A Feasibility Study of Additively Manufactured Composite Tooling

Max D. A. Valentine, Arjun Radhakrishnan, V. Maes, E. Pegg, Maria D. R. Valero, J. Kratz, V. Dhokia
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Abstract

As the flexibility and reliability of additive manufacturing (AM) and its corresponding design tools increases, it is becoming a viable option for more industries. One application area that could benefit from AM is composite component manufacture. The layup and molding of composite materials face significant challenges presented by tight design timescales, growing demand for productivity, and the complexity of components and end products. Therefore, there is an immediate potential to save energy by reducing the mass of the curing equipment and tooling to enhance process heat transmission. The goal of this paper is to demonstrate the reduction of embodied energy within mold tools that are printed using an AM process. Using an AM approach, it is possible to design lightweight curing tools to increase the curing rate and quality of heat distribution in the mold. The viability of additively producing these cure tools was assessed by analyzing the geometrical precision of the composite mold outputs, material utilization, and heat transmission qualities of each sample. In this study, 14 cure tools were designed and manufactured with a 100 mm2 curing surface area, top plate thickness of 1–2 mm, and stiffening lattices behind the curing surface with a depth of 10 mm. Four lattice geometries, gyroid, dual-wall gyroid, planar diamond, and stochastic, were tested based on their overall geometrical accuracy and thermal responsiveness. While the stochastic lattice had the best single tool properties, the planar diamond and gyroid lattice tools had better potential for future use in the design of additively manufactured composite tooling.
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增材制造复合材料模具的可行性研究
随着增材制造(AM)及其相应设计工具的灵活性和可靠性的提高,它正在成为更多行业的可行选择。可以从增材制造中受益的一个应用领域是复合部件制造。复合材料的铺层和成型面临着紧迫的设计时间尺度、不断增长的生产率需求以及组件和最终产品的复杂性所带来的重大挑战。因此,通过减少固化设备和工具的质量来增强过程传热,可以立即节省能源。本文的目标是演示使用增材制造工艺打印的模具工具中体现的能量的减少。使用AM方法,可以设计轻量级的固化工具,以提高固化速度和模具中热分布的质量。通过分析复合模具产出的几何精度、材料利用率和每个样品的传热质量,评估了增材生产这些固化工具的可行性。在本研究中,设计和制造了14个固化工具,固化表面积为100 mm2,顶板厚度为1-2 mm,固化表面后面的强化格深度为10 mm。基于几何精度和热响应性测试了四种晶格几何形状,即陀螺、双壁陀螺、平面金刚石和随机几何形状。随机点阵刀具具有最佳的单刀具性能,而平面点阵刀具和旋转点阵刀具在增材制造复合材料刀具设计中具有更好的应用潜力。
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