DMLS OF INJECTION MOULD INSERTS FROM 2004 UNTIL TODAY · DMLS OF INJECTION MOULD INSERTS. FROM 2004...

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LASERGENERATING INNOVATIVE AND UNCONVENTIONAL MANUFACTURING EOS user meeting 2011 © LBC GmbH DMLS OF INJECTION MOULD INSERTS FROM 2004 UNTIL TODAY LBC LaserBearbeitungsCenter GmbH Im Moldengraben 34 D-70806 Kornwestheim Tel.: 07154/80 88 - 0 Fax: 07154/80 88-28 E-Mail: [email protected] Internet: www.Lasergenerieren.de .

Transcript of DMLS OF INJECTION MOULD INSERTS FROM 2004 UNTIL TODAY · DMLS OF INJECTION MOULD INSERTS. FROM 2004...

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    DMLS OF INJECTION MOULD INSERTS

    FROM 2004 UNTIL TODAY

    LBC LaserBearbeitungsCenter GmbH Im Moldengraben 34 D-70806 Kornwestheim Tel.: 07154/80 88 - 0 Fax: 07154/80 88-28

    E-Mail: [email protected] Internet: www.Lasergenerieren.de

    .

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    • Needs for the futureTechnology (EOS)

    Market

    • DMLS current status• Basics about LBC

    engineering solutions

    Implementation,

    Here we are today

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    • Needs for the futureTechnology (EOS)

    Market

    Possible mould solutions

    • DMLS current status• Basics about LBC

    engineering solutions

    Implementation,

    Here we are today

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    LBC offers the generative manufacturing of metal parts since 2004 as a service. Therefore LBC is one of the pioneers using this technology, especially in mould and diecasting applications. At the beginning we used the Trumaform LF 250 from TRUMPF.Since 2006 LBC is using the M270 from EOS.

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    LBC was able to boost the acceptance and request for lasergenerated moulds, prototypes and serial parts constantly. In March 2008 the manufacturing capacity was increased to 2 machines. In December 2009 the third machine was installed.

    Air conditioned manufacturing cell

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    Today LBC is especially for the mould and diecasting market the service supplier with the biggest manufacturing capacity for lasergenerated parts in Germany.

    Facts:

    approx. 95% of the lasergenerated parts are . conformal cooled inserts.

    approx. 4% of the lasergenerated parts are . for serial applications

    approx. 1% of the lasergenerated parts are . prototyps.

    2010 LBC was consuming approx. 1600 kg . of the material 1.2709, tendency is increasing.

    One bottle corresponds with10 kg powder material

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    • Needs for the futureTechnology (EOS)

    Market

    • DMLS current status• Basics about LBC

    engineering solutions

    Implementation,

    Here we are today

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    engineering:

    LBC is now commercially introducing a professionally engineered approach. The focus of this approach is analyzing new or existing moulds, reviewing the thermal efficiency, then optimize the design, resulting in the manufacture of Tailored conformal cavity cooling.

    As experts in the lasergenerating manufacturing processes as well as our strength in developing and designing injection moulding tools LBC can offer you the opportunity to see what can do for your projects.For the best part quality and most efficient production, should be your first choice.

    is the LBC brand for individual, customer specific solutions with conformal cooling and the manufacturing of lasergenerated mould inserts.

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    The technology Lasergenerating is offered by LBC as services. Since 2004 we were able to establish a hugh know-how. This knowledge is the base to realize customer wise tasks. Especially for new customers our detailed helpdesk is the needed support to erase the respect or fear regarding this new technology In an open discussion about all facts, the customer receives all background information he needs. This is the base for a good, future cooperation and the key for our success.

    engineering - helpdesk:

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    In order to support our customers when optimizing the realisation of conformal cooled inserts and moulds, LBC offers the design of the channel inside the customer's mould. LBC provides the customer with the design data in 3 D for their approval.

    engineering - design:

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

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    This conformal cooling system is used in an insert since more than 4 years. Geometry:Ellipse standing 1,3 mm x 1,8 mmequates Ø 1,53 mm2 closed loops 1x 4-times parallel

    1x 5-times parallelIs running with 6 bars and filteringCooling medium: water

    Total length of all channels is 12.500 mm!

    Cooling cycle is the half!

    Information:

    engineering - design:

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    Geometry:Ellipse standing 1,3 mm x 1,8 mmequates Ø 1,53 mm1 closed loop 1x 4-times parallelEach channel is 800 mm long.

    Is running with 3 bars Cooling medium: water

    Total length of all channels is 3.200 mm!

    Flow demonstration:

    engineering - design:

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    Complex mould require an extensive design to realize a perfect cooling.This design is based on fundamental know-how of the designer. So it was possible to provide this channel system.8 channels with Ø 3 mm and nearly identical length branch out of a 10 mm input. This guaranties identical flow in all channels.

    Information:

    engineering - design:

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    Sample of an extensive design to realize a perfect cooling.

    Information:

    engineering - design:

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    The simulation of the expectable cycle time reduction is no manageable with any simulation software, because of the complexity of the conformal cooling systems caused by Lasergenerating. As simulation is the key to check on the efficiency of cooled inserts, LBC offers this simulation as a service. So the customer's purchasing department receives facts for their decision.

    engineering - simulation:

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    The simulation of a conformal cooling is done together with a flow analysis. Using the software LBC has a tool, to implement the total design of conformal cooling channels.

    Therefore we need the following

    article as 3D CAD data,

    injection points,

    form of the injection (e.g. hot runner),

    plastics with data sheet,

    process parameters injection

    CAD data of the conventional cooling,

    cooling data, flow volume, pressure, number of closed loops, temperatures etc.

    Information:engineering - simulation: basics

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    Information:engineering - simulation: Temperature difference

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    engineering - simulation: Reynolds number

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    • Needs for the futureTechnology (EOS)

    Market

    Possible mould solutions

    • DMLS current status• Basics about LBC

    engineering solutions

    Implementation,

    Here we are today

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    Laser generated cooling core insert for a 2- components injection mould for an ice scraper.By the integrated cooling ducts close to contour, the cycle time could be reduced from 80 seconds to 40 seconds.Thus allows the production of twice as much parts.

    Information:

    realized mould inserts

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    conformal cooled insert with closed loop cooling channels

    Information:

    realized mould inserts

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

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    Thermografy:

    realized mould inserts

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    Information:Reduction of the generatable volume to the needed minimum for an effective cooling.

    Dramatically reduce of the manufacturing costs.

    Gain of the lasergenerating profitability.

    More effective use of the laser capacity.

    Signification of the hybrid technology

    Lasergenerating on a premanufactured hybrid blank

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    Information:

    1.2709 (Böhler W722 VMR) deliverable up to Ø122 mm turned and as 150 x 150 mm square

    Vacumar from Zapp, martensite steel analogue 1.2709. All dimensions are deliverable.

    The use of 1.2343 or 1.2083 is not possible!! You will have a big danger for cracks.

    Fitting basic material:

    Lasergenerating on a premanufactured hybrid blank

    Crack of a hybrid blank1.2083 (hardened)

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    Insert lasergenerated on a hybrid blankUsing this premanufacturedvolume the production cost could be dropped 50%.The hybrid material has to be also 1.2709 mould making steel.

    Information:

    realized mould inserts, using a hybrid blank

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    Conformal cooled mould insert, on a premanu-

    factured hybrid blank. Without using the hybrid solution, this insert would not have been manageable economically and the run time of the machine would have been to long.

    Information:

    realized

    mould

    inserts, using

    a hybrid blank

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    • Needs for the futureTechnology (EOS)

    Market

    Possible mould solutions

    • DMLS current status• Basics about LBC

    engineering solutions

    Implementation

    Here we are today

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    Here we are today

    In 2004 the acceptance of the lasergenerating was more or less ZERO. Nearly no mould maker wanted to believe in this new technology. A lot of question had to be answered and it was a hugh challenge to get the first orders.

    Nearly no mould maker wanted to be first!

    They did not accept the surface roughness and could not believe that the material property will fit to their needs.

    Detecting the outside zero point with a touch probe was not as easy as with today's surfaces, built on a M270.

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    Here we are today

    Surface roughness of an insert produced on the Trumaform LF250 at LBC. Material: 1.2343 Layer thickness: 0,1 mm

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    Here we are today

    Surface roughness of an insert produced on the M270 at LBC. Material: 1.2709 Layer thickness: 0,04 mm

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

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    Here we are today

    Limits:The volume rate is still limited

    The maximum size of generatable inserts is limited

    Will the channels get blocked?

    Is the material property good enough?

    What is the lifetime of such an insert?

    Will the higher costs be paid by the injection moulder, who has the benefit?

    Still no content of teaching at Universities

    Still no content of teaching at professional schools

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    Technology EOS:

    The new M280 is an important step into the right direction.

    The volume rate will be growing nearly 100%.

    Parts up to 300 mm, especially hybrid solutions, can be lasergenerated in . one piece.

    Here we are today

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    • Needs for the futureTechnology (EOS)

    Market

    • DMLS current status• Basics about LBC

    engineering solutions

    Implementation,

    Here we are today

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    Technology EOS:

    LBC’s wishes for the next generation of M-series are:

    The volume rate should be improved as much as possible

    More different sizes of the building chamber

    This machine has to be designed for mass production issues

    Costs down, especially for spare parts and service

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    • Needs for the futureTechnology (EOS)

    Market

    Possible mould solutions

    • DMLS current status• Basics about LBC

    engineering solutions

    Implementation,

    Here we are today

  • LASERGENERATINGINNOVATIVE AND UNCONVENTIONAL MANUFACTURING

    EOS user meeting 2011 © LBC GmbH

    Market:

    Having machines with highest productivity the market would be enormous.

    Starting with the M280 we will able to compete against several other solutions of conformal cooling as:

    soldered inserts

    diffusion welding

    hugher and longer inserts will be manageable

    New application will follow step by step!

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