single-au.php

IJAT Vol.6 No.5 pp. 584-590
doi: 10.20965/ijat.2012.p0584
(2012)

Paper:

Design Method for Inner Structure of Injection Mold Fabricated by Metal Laser Sintering

Hiroshi Koresawa, Hirofumi Fukumaru, Michio Kojima,
Jun Iwanaga, Hiroyuki Narahara, and Hiroshi Suzuki

Department of Mechanical Information Science and Technology, Kyushu Institute of Technology, 680-4 Kawazu, Iizuka-shi, Fukuoka 820-8502, Japan

Received:
April 12, 2012
Accepted:
July 20, 2012
Published:
September 5, 2012
Keywords:
additive manufacturing, metal laser sintering, injection mold, structure design, layered fabrication
Abstract

This paper discusses design methods for the internal structure of molds used in production utilizing metal laser sintering combined with high speedmilling which selectively sinters metal powder to form a three dimensional mold. This milling technique is characterized by the fact that the selective laser sintering process and milling process are carried out in alternating sequence, achieving the level of processing accuracy demanded of mold production. In addition, in the selective laser sintering process, because the mechanical strength of the sintered body (Young’s Modulus) is variable, suitable interior structures that consider dynamic conditions are expected. However, in the current state of design, this structure is determined experimentally, and there is a high possibility of incurring unnecessary production time and high costs. In this paper, we investigate a method that incorporates an optimization method using stress that occurs within the structure interior, obtains the interior topological structure as a Young’s Modulus distribution, and designs a suitable interior structure using this distribution. As a result of investigation using numerical analysis, we obtained a structure that reduces the volume of the sintered body, having high mechanical strength in comparison with a conventional structure while improving structural rigidity.

Cite this article as:
H. Koresawa, H. Fukumaru, M. Kojima, <. Iwanaga, H. Narahara, and H. Suzuki, “Design Method for Inner Structure of Injection Mold Fabricated by Metal Laser Sintering,” Int. J. Automation Technol., Vol.6, No.5, pp. 584-590, 2012.
Data files:
References
  1. [1] S. Abe, Y. Higashi, H. Togeyama, I. Fuwa, and N. Yoshida, “Development of milling-combined laser metal sintering method – Combination of laser-assisted metal sintering method and the milling in one machine –,” J. of the Japan Society for Precision Engineering, Vol.73, No.8, pp. 912-916, 2007. (in Japanese)
  2. [2] A. Yassin, T. Ueda, T. Furumoto, A. Hosokawa, R. Tanaka, and S. Abe, “Experimental investigation on cutting mechanism of laser sintered material using sall ball end mill,” J. of Material Processing Technology, Vol.209, pp. 5680-5689, 2009.
  3. [3] T. Furumoto, T. Ueda, T. Tsukamoto, N. Kobayashi, A. Hosokawa, and S. Abe, “Study on Laser Consolidation of Metal Powder with Yb: fiber laser – Temperature Measurement of Laser Irradiation Area –,” J. of Laser Micro/Nanoengineering, Vol.4, No.1, pp. 22-27, 2009.
  4. [4] T. Yoneyama and H. Kagawa, “Fabrication of Cooling Channels in the Injection Molding by Laser Metal Sintering,” Int. J. of Automation Technology, Vol.2, No.3, pp. 162-167, 2008.
  5. [5] M. Kojima, H. Narahara, Y. Nakano, H. Fukumaru, H. Koresawa, and H. Suzuki, “Permeability Characteristics and Applications of Plastic Injection Molding Fabricated by Metal Laser Sintering Combined with High Speed Milling,” Int. J. of Automation Technology, Vol.2, No.3, pp. 175-181, 2008.
  6. [6] T. Yoneyama, K. Naito, S. Abe, and M. Miyamaru, “Reduction of Injection Pressure for Thin Walled Molding using the Laser Metal Sintered Mold,” J. of the Japan Society for Precision Engineering, Vol.76, No.2, pp. 188-192, 2010. (in Japanese)
  7. [7] S. Sato and T. Okamura, “Automatic Mold Design System Synchronized with Product Design Data and Logical Analysis of Mold Design,” J. of the Japan Society of Mechanical Engineers (series C), Vol.73, No.736, pp. 4-9, 2007. (in Japanese)
  8. [8] S. Nishiwaki, M. I. Frecker, S. Min, and N. Kikuchi, “Topology Optimization of Compliant Mechanisms Using the Homogenization Method,” Int. J. for Numerical Methods in Engineering, Vol.42, Issue 3, pp. 535-559, 1998.
  9. [9] D. Reynolds, J. McConnachie, P. Bettess, W. C. Christie, and J. W. Bull, “Reverse adaptivity – a new evolutionary tool for structural optimization,” Int. J. for Numerical Method in Engineering, Vol.45, Issue 5, pp. 529-552, 1999.
  10. [10] H. A. Eschenauer, H. A. Kobelev, and A. Schumacher, “Bubble method for topology and shape optimization of structure,” Structural and Multidisciplinary Optimization, Vol.8, No.1, pp. 42-51, 1994.
  11. [11] X. Y. Kou, G. T. Parks, and S. T. Tan, “Optimal design of functionally graded materials using a procedural model and particle swarm optimization,” Computer-Aided Design, Vol.44, Issue 4, pp. 300-310, 2011.
  12. [12] S. R. Johnston, M. Reed, H. V. Wang, and D. W. Rosen, “Analysis of Mesostrucure Unit Cells Comprised of Octet-truss Structures,” Proc. of the Seventeenth Solid Freeform Fabrication Symposium Austin, TX, pp. 421-431, 2006.
  13. [13] N. Inou, N. Shimotai, and H. Kobayashi, “Cellular Automaton Self-Organizing a Mechanical Structure. Behavior of Total System Generated by Local Rules,” J. of the Japan Society of Mechanical Engineers (series A), Vol.61, No.586, pp. 1416-1422, 1995. (in Japanese)

*This site is desgined based on HTML5 and CSS3 for modern browsers, e.g. Chrome, Firefox, Safari, Edge, IE9,10,11, Opera.

Last updated on Nov. 08, 2019