Lecture 1 part 2 Flashcards
What are 3 problems with ocnventional tooling?
High cost, long lead times, allows for few design iterations
Explain indirect and direct tooling
indirect tooling produces a pattern from which the tool is produced (like a mould)
direct tooling manufacturers directly from sliced CAD data (It is often used for injection moulds and sometimes for die casting)
Fill in the Process chain of direct tooling
Sort the following features into advantages and disadvantages for direct rapid tooling
Surface finish
Relationship with software
Geometrical accuracy
Tool mass
Cost
Production scale
Lead time
Tool complexity
Advantages are
Lead time
Cost
Tool complexity
Tool mass (less as a result of increased complexity)
Surface fnish requires post finishing
Full geometrical accuracy is not perfect
Production scales are limited to small/medium batches, depending on material choice
Software is always playing catchup with the hardware tech
Additive manufacturing methods allow conformal heat distribution channels to be built into the tool during manufacture. How do these channels help the tools performance? (5 points)
increase rate of heat transfer which decreases cycle time
allow control of temperature distribution in mould which improves the consistency of mould
channels mean less mass, meaning less energy and time required to heat/cool the mould
increase effective thermal diffusivity
reduce material use and build time
Rapid tooling limits material choice, but also allows for new kinds of materials to be used, such as functionally graded materials. What are they?
Materials which can be designed according to their composition and structure for specific functions
When should you use hybrid tooling?
This decision depends on how many parts are needed and what the production material of the parts is. Normally advantages from both traditional and non traditional tooling methods can be gained.
Give 2 examples of how hybrid tooling can be used to gain the advantages from both traditional and non traditional methods
Eg 1 AM core and machined cavity combines internal complexity and best A-surface finish
Eg 2 Machined tools may include layer manufactured inserts for engineering changes
Give 2 examples of public misconception of Additive Manufacturing
The name rapid (from prototyping) can be misleading for those who dont understand the technology
AM should be thought of as another tool for manufacturing where appropriate, not as a technology capable of revolutionising and replacing current industry methods
high _____ _____ aspects offer advantages for this tech aswell as just speed and cost
Increases ______ _______ and potential for expression because there are less design for manufacture and assembly criteria
‘new and improved’ method gains favour with _________
____________ (weight, strength, fluid flow, heat transfer) is possible as a result of increased geometrical complexity
remember small ______ savings for individual components have large positive effects in larger application
potential end of life ________ (single material)
no need for assembly meaning less ____ requirement and likelihood of _____
high added value aspects offer advantages for this tech aswell as speed and cost
Increases design freedom and potential for expression because there are less design for manufacture and assembly criteria
‘new and improved’ method gains favour with consumers
optimisation (weight, strength, fluid flow, heat transfer)
is possible as a result of increased geometrical complexity
remember small weight savings for individual components have large positive effects in larger application
potential end of life recycling (single material)
no need for assembly meaning less cost requirement and likelihood of error
Why is additive manufacturing very well suited for personalised products?
Provides the capability for individual complex parts to be produced in batches.
Has the ability to allow customisation/personalisation, without requiring expert knowledge.
The market is emerging alongside software and websites which are taking advantage of this suitability and growing the market currently.
give a brief example of an application of AM like the examples of the lamps and jewellery in the lecture
Examples should demonstrate the following:
Beginning with a broad design template, with relevant rules and relationships.
The design should be able to continuously change within these boundaries, maintaining a
certain aesthetic but with potentially infinite unique designs; allowing full customer choice whilst maintaing a brand
