1. AEPR 2004 14-15 September A first approach to choose between HSM, EDM and DMLS processes in Hybrid Rapid Tooling P. Mognol 1, M. Rivette 2, L. Jégou 1, T. Lesprier 1 (1) IRCCyN, 1 rue de la noé, BP92101, 44321 Nantes Cedex email: mognol@bretagne.ens-cachan.frmognol@bretagne.ens-cachan.fr (2) ENS Cachan - Antenne de Bretagne, Campus de ker Lann 35 170 BRUZ

2. AEPR 2004 14-15 SeptemberOutline: Introduction: general Context Hybrid Rapid Tooling (HRT) Hybrid Rapid Tooling (HRT) manufacturing : A method to optimize the processes in Hybrid Rapid Tooling. Validation of method : Test with an industrial mould Conclusions and prospect

3. AEPR 2004 14-15 September Introduction: general Context These last years the moulded products are increasingly present in the technical systems : products have become more complex life-cycle become more shorter Appearance of the « Hybrid Rapid Tooling » Launching time and cost must be reduce Real prototypes are necessary to test style, technical functions, or industrial dies Every functions must be tested

4. AEPR 2004 14-15 September For every results witch don’t match with functional requirements we must Re- designing and manufacturing only one component of mold. Prototype Part Design Test Hybrid manufacturing Validation of part design Re-designing of one or several component(s) Test OK Test not OK HRT : Validation of part design and evolution product Multi components Prototype partitioning Assembly components Hybrid rapid Tooling with same characteristic as cast solid tools Rapid Tooling 

5. AEPR 2004 14-15 September Hybrid rapid tooling : Analysis Multi component prototype MCP Assembly analysis Feasibility Analysis geometry analysis Assembly must respect initial positioning of the geometric features in the single piece part and technical constraints Analyzes functional (ISO specifications), evolutionary criterions and topologic configuration. Propose the best manufacturing process for each component of the studied MCP. Propose a 3D puzzle of the part with the topologic and geometrical criterions Manufacturing analysis

6. AEPR 2004 14-15 September Time Cost Quality HSM DMLS ( EDM if pb ) Triptych CDC Hybrid Rapid tooling Hybrid rapid tooling manufacturing: Need method for choice Need method for making a judicious choice between HSM, DMLS and EDM Volume of DMLS €€ Temps To compress the total time To reduce ! Simultaneous manufacture Finish HSM DMLS EDM

7. AEPR 2004 14-15 September Hybrid rapid tooling manufacturing: Help choice process Feature recognition  Sj  Si 6 types of geometry + Associated choice process Topological and processes analyses DMLS or HSM DMLSHSM EDM Feature with choice: “HSM or DMLS” Feature without Choice: “HSM” or “DMLS”  Si HSM or DMLS  Sj HSM or DMLS  Sk HSM or DMLS  Sl / DMLS DMLS  Sm / HSM HSM  SolutionHSM Table of propagation Final choice DMLS or HSM

8. AEPR 2004 14-15 September Hybrid rapid tooling manufacturing : 1) feature recognition Topological Analyze Feature Exterior volume Manufacturing problems Topological association because same Pb of manufacture Simple feature Large complex feature Little complex feature Simple feature Large complex feature Little complex feature DMLS EDM HSM DMLS EDM HSM DMLS EDM HSM DMLS EDM HSM DMLS EDM HSM DMLS EDM HSM Particular case Interior volume

9. AEPR 2004 14-15 September HRT manufacturing : 2) Topological and processes analyses DMLS or HSM DMLSHSM EDM DMLS or HSM

10. AEPR 2004 14-15 September HRT manufacturing :3) Table of propagation HRT manufacturing : 3) Table of propagation  Sm  Sn Geometrical intersection Feature without choice Ex: HSM Feature with choice Ex: HSM or DMLS HSM Propagation

11. AEPR 2004 14-15 September HRT manufacturing :3) Table of propagation. (example) HRT manufacturing : 3) Table of propagation. (example) Iteration as long as there are features « with choice » Feature with choice: “HSM or DMLS” Feature without Choice: “HSM” or “DMLS”  Si HSM or DMLS  Sj HSM or DMLS  S… HSM or DMLS  So HSM or DMLS  Sa / HSM HSMNo intersection …  S… …………  Sf / DMLS DMLS …No intersection  SolutionHSMDMLS… HSM or DMLS

12. AEPR 2004 14-15 September To validate the DMLS Process for obtaining Rapid tooling for preproduction of connections in "ABS charged glass fibres". Goal Low dimensions the mould requires EDM to obtain the thin feature (special threading, forms interiors of the head, mini blending radius…). Problematic Test for a mould :Validation of the DMLS Test for a mould : Validation of the DMLS

13. AEPR 2004 14-15 September Prototype part design CAM Rapid tooling (DMLS) Plastic injection Validation of process DMLS for obtaining the connections in "charged ABS" Test for a mould :Validation of the DMLS Test for a mould : Validation of the DMLS

14. AEPR 2004 14-15 September Feature recognition  Sl SkSk  Sj  Si SmSm Example: « lower and higher mould » Topological and processes analyses R 7.5 R 4 R=0 if not not specified in CAD Test for a mould : Manufacturing a HRT.

15. AEPR 2004 14-15 September Test for a mould :Manufacturing a HRT. Test for a mould : Manufacturing a HRT. Tool specifications  Si Little complex l/h = 1.01 and l = 15 and IT>0.1 L/d(tool)=1 and h=7.5 HSM or DMLS Interior feature Surfaces identification Topological analysis  Sj Thin complex l/h = 1,5 and l = 5 and IT>0.1 L/d = 0.5 and h =6 Interior feature HSM or DMLS  Sk Thin complex l/h = 0.8 and l = 8 and IT>0.1 L/d=1 and h=4 Interior feature HSM or DMLS  Sm Simple L*l = 33.2*25L/d = 3 and h = 5 Exterior Feature HSM  Sl Thin complex l = 0.18 IT>0.1 r = 0 d(tool)=0.18 Interior Feature DMLS Stage 1 Stage 2 DMLS HSM HSM or DMLS

16. AEPR 2004 14-15 September Test for a mould : Manufacturing a HRT. Feature with choice: “HSM or DMLS” Feature without Choice: “HSM” or “DMLS”  Si HSM or DMLS  Sj HSM or DMLS  Sk HSM or DMLS  Sl / DMLS DMLS  Sm / HSM HSM  SolutionHSM Table of propagation Stage 3 We choose the HSM process for manufacturing  Si,  Sj,  Sk et  Sm

17. AEPR 2004 14-15 September Application of a color code Integration of the different parts and obtaining the "hybrid" mould Hybrid rapid tooling manufacturing: HSM DMLS Test for a mould :Manufacturing a HRT. Test for a mould : Manufacturing a HRT.

18. AEPR 2004 14-15 September SjSj SlSl SkSk SiSi SmSm  Sn  So  Sp HSM EDM DMLS Test for another application « Color code »

19. AEPR 2004 14-15 September Test for a mould : Manufacturing a HRT. Winnings estimation 18% 15% DMLS Hybride DMLS

20. AEPR 2004 14-15 September Conclusions and prospect Multi component prototype MCP Assembly analysis Feasibility Analysis geometry analysis Assembly must respect initial positioning of the geometric features in the single piece part and technical constraints Analyzes functional (ISO specifications), evolutionary criterions and topologic configuration Propose the best manufacturing process for each component of the studied MCP Propose a 3D puzzle of the part with the topologic and geometrical criterions Manufacturing analysis method validated on these examples automation of the feature recognition Synthesis

21. AEPR 2004 14-15 September Thanks for your attention Contacts: Mickaël Rivette ENS Cachan - Antenne de Bretagne - Rivette@bretagne.ens-cachan.fr Pascal Mognol ENS Cachan - Antenne de Bretagne - Mognol@bretagne.ens-cachan.fr