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INTRODUCTION
The term Rapid Tooling is typically used to describe a
process that either uses a rapid prototyping model as a pattern to create molds quickly or uses the rapid prototyping process directly to fabricate tools for a limited volume of prototypes.
The most RT approaches utilizes multi step procedures
CLASSIFICATION OF RT ROUTES
Rapid tooling techniques have been classified in
production. Hard tooling is the opposite, refer to tools required for large quantity production.
tooling is usually produced from soft materials such as silicon, rubber, epoxies, zinc alloys, aluminum etc.
Much hard tooling in industry is produced by means of
(CNC)
and
the prototype, these techniques can directly supply the production tool.
RP OF PATTERNS
A
critical element of any casting technology, conventional or otherwise is the master pattern. Many times the pattern is of complex geometry with fine detail.
patterns, many industries have applied investment casting and precision casting for the fabrication of rapid production tooling.
The RP approaches used to pattern making include SL,
laminated
object
can be melted away. The patterns are produced from female cavity dies and assembled on a common gating system. The assemblage is called a cluster.
INDIRECT RT
The indirect method uses RP master pattern to produce a
mold. Silicon rubber molding and epoxy tooling are some examples of indirect methods.
There are various indirect methods for soft and bridge
temperature
vulcanizing
silicon
rubber
molds) 2. Nickel Ceramic Composite (NCC) tooling 3. Composite aluminum filled epoxy (CAFE) tooling 4. Rapid mold process
fashion in the z-direction to determine the geometry of a Single integrating matching plate electroforming (SIMPLE) tool model.
using
conditions
favoring
good
is next attached to the mold frame using a set of clamp-ring buss bars.
6. Next, the ceramic is vacuum cast through a small
holes for ejector pins. Nickel is softer than most tool steels.
production tooling. It means that production tooling must be much more durable than soft and bridge tooling.
A widely used indirect RT process for production
cavity mold inserts, followed by the creation of the core and cavity patterns by means of SL.
hardened, the insert is taken out and placed in a furnace so as to melt the binder out and bring the insert to a green state.
The pattern with the low melting point is then easily
tolerances of the order of 50m. Through appropriate heat treatment, the inserts can be hardened.
produce metal tooling. Traditional methods of investment casting with injection molding is compared with investment casting using RP.
ceramic slurry, which are allowed to dry between coats. After the shell has dried, the ceramic shell and
the invested model to burned out. After firing, any ash residue is washed away from the ceramic shell.
The molten alloy of the tool material is then poured
fractured and the newly formed metal cavity is removed and postprocess machined.
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