MoldMaking Technology

FEB 2018

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moldmakingtechnology.com 31 cylinder is placed into the system, it moves automatically to its setup and working position. The integrated zero-point clamping system is the basis for downstream process steps such as EDM, milling and turning. Integration into Existing Processes The catchphrase is process integration. The future of AM lies in its integra- tion into current manufacturing processes to reduce steps, time to market and costs. The future of AM also lies in the intelligent combination of convention- al machining technologies and AM. AM processes have long been considered stand-alone technologies that did not fit easily into machining process chains. Marketing strategies were sug- gesting that one either manufactures with conventional subtractive machin- ing technologies or with AM technologies. Many production managers simply never realized that these two worlds can and should be combined to yield the most optimum results. This is particularly true for moldmaking, where AM has long found its place in the integration of conformal cooling channels in molds and mold inserts. Laser sintering is useful as well for making sintering density changes in molding applica- tions that require the placement of porous structures to facilitate gas venting. In addition, laser sintering enables the production of deep features by building them one layer at a time, eliminating the need to machine these features with EDM. Two companies that realize moldmakers need solutions, not single machines or technologies, are GF Machining Solutions and EOS, and they have partnered to combine their technologies to benefit the moldmaking sector. The AM S 290 Tooling machine, which is based on the EOS M 290 DMLS system, is designed to address the mold and die industry's need to produce innovative mold inserts using AM. GF Machining Solutions and EOS aim to integrate AM machines into the production process of mold inserts, including the necessary software and automation link with downstream machine tools and measuring devices. The Technical Unit System 3R zero-point clamping solution from GF Machining Solutions works in a similar fashion to the Trumpf zero-point clamping system. The Technical Unit System 3R ensures that the workpiece moves along the various production steps maintaining the same zero-point, eliminating errors and setup times. The system consists of a reference platform (3R Masterpal) and multiple component-specific mini pallets (3R Minipal) on which additively manufactured parts are printed. This can be particularly useful when manufacturing hybrid parts. The first step in producing hybrid parts is milling or turning where the workpiece is set up, referenced and machined. To add material via selective laser melting (SLM) or other AM processes, the part is placed into the AM machine and usually loses all of its reference points. The same is true for post-processing steps like mill- ing. Using the reference platform eliminates multiple setups and corresponding errors. Since the additive process is quite expensive, conventionally machining the core or the insert and reserving AM only for the parts with conformal cool- ing channels is a cost-efficient solution for mold shops producing hybrid parts. Hybrid Machines Offer the Best of Two Worlds Hybrid AM machines offer a combination of layer-by-layer building and conven- tional subtractive machining. Consequently, the giants of the wider manufactur- ing world did not miss the opportunity to showcase their latest developments at Formnext. Companies with something to display included DMG MORI, Matsuura, Hermle, OR Laser and Sodick. • Compact w/ Multiple Mounting Options • Greater Max Pressures & Stroke Range • Quality Control: Better Steel, Extra Seals, & 100% Pre-Tested • The Only Small Block Cylinders with Integrated Switches We Only Make MOld Cylinders injection Molding is in Our dna For Sales and Support in North America contact: Call: 909.941.0600 www.albaent.com Design custom cylinders and download 2D & 3D files, catalogs & tech manuals. Register Now at: VegaCylinder.com Configure Your CYlinders

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