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3 Year Aluminum Tooling Study Power Point Presentation

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  • 1. Toll Free # 800-826-3370
  • 2.
    • Aluminum has 5 times better heat transfer than P20 steel
    • Aluminum has almost 6 times better heat transfer compared to H-13 Steel.
    • Molders have experienced a 20% to 40% faster cycle time.
    Toll Free # 800-826-3370
  • 3.
    • Aluminum Mold can be machined up to 30% faster overall with appropriate high speed CNC machines and cutting tools specifically designed for aluminum
    • Polishing time is reduced.
    • Aluminum is 1/3 the weight of steel.
    • Service Centers can ship aluminum within
    • 1-3 days, versus steel.
    Toll Free # 800-826-3370
  • 4.
    • Aluminum alloys offer higher thermal conductivity, so the parts are removed at a lower temperature. This leads to better dimensional stability of parts providing higher yields on the molding process.
    Toll Free # 800-826-3370
  • 5.
    • Cast product with three North American Producers
    • Available in North American up to 30" thick and 74" wide (only 20” thick at this width)
    • This alloy is for low volume or prototype molds.
    • No abrasive plastics
    •        
    • Drawbacks
    •         Heat transfer is slower due to the low copper content   / Cycle times are going to be slightly lower than other aluminums
    •         Hardness is low 70 HB
    •         yield and tensile strengths are lower than other aluminums available
    •         Because of the hardness a high polish is hard to achieve
    •  
    • Benefits
    •          Cost - Weight .96 dense
    •         because its a cast plate cost is much less than rolled or forged block
    •         Machinability is very good due to the lack of copper content
    •         stability is the best of any aluminum
    •         Has great weldability
    •         because copper content is low the corrosion resistance is very high
    •         sizes available
    •         through hardness
    •  
    Toll Free # 800-826-3370 Trade Names: Alpase – K100S & M 5 Vista – ATP-5 & Duramold 5
  • 6.
    • Cast product with two North American Producers
    • This alloy has higher yield and tensile strengths than 6061 with hardness very close to 6061
    • can be used for low volume production and prototype tools
    • sizes available 38 thick 94 wide
    •  
    • Drawbacks
    •     Machinability (This is within the aluminums available / Still would machine much better than steel) Chips might stick to cutters gummy.
    •     hardness is low (again within the aluminums available) 82 to 90HB
    •     Polishability
    •  
    • Benefits
    •     Cost compared to 6061/ 7000
    •     weldability
    •     heat transfer very high
    •     yield and tensile strength are high compared to 6061
    •     sizes available
    •     through hardness
    Toll Free # 800-826-3370 Trade Names: Alpase – M1 Vista – Duramold 2
  • 7.
    •                                
    • rolled plate
    • 16 thick
    • 84 wide
    • 192 long
    •  
    • Drawbacks
    •     Machinability is poor
    •     hardness 89 -96 HB
    •     Polishability
    • Benefits
    •     thermal transfer rate is high
    •     cost compared to 7000 series
    •     weldability
    Toll Free # 800-826-3370 Trade Names: Kaiser select
  • 8.
    • Three available alloys besides 7075
    • available 28” thick in forged block
    •  
    • Drawbacks
    •     Weldability /  Can be welded but you have to follow the welding instructions very carefully
    •     Stability - All 7000 series can move during machining if not stress relieved
    •  
    • Benefits
    •     BTu's are very high 88- 100
    •     Machinability
    •     Yield and Tensile strengths are very high
    •     sizes available
    •     Hardness 150- 180 HB
    •     Polishability  A mirror finish is achievable
    Toll Free # 800-826-3370 Trade Names: Aleris – Hokotol Alcan – Alumold 7075 – General product
  • 9.
    • Their approach for reviewing Aluminum Alloy
    • 1. Met with key Aluminum Alloy Material Suppliers
    • 2. Honda paid for 3rd Party Testing to validate Material composition,
    • mechanical properties, abrasion resistance and compression strength.
    • 3. Concluded that Honda should begin working with its suppliers to build Aluminum Alloy Tools. (ZQ/WQ)
    • 4. Honda decided to build aluminum tools and pay for the backup Steel Tool
    • Purpose: a. Review Clamping pressure
    • b. Review injection pressure
    • c. Evaluate Tool build efficiencies
    • d. Evaluate Process Cycle time
    • 5. Honda paid for Texture plaque development to further understand Aluminum Alloy texture capabilities as well as repair methods.
    • 6. Monitor Tool Maintenance and durability concerns
    • 7. Based on Low Volume Results, began focusing on High Volume
    • applications to validate AL Alloy durability.
  • 10.  
  • 11.
    • Can the mold be crushed by too much pressure?
    • Unit stress = load/area
    • Projection area of mold = 46 x74 = 3404 in2
    • Projection area of part = 955 in2
    • Contact area = 3404 - 955 = 2449 in2
    • Stress (2500 ton press) =5,000,000 / 2449 = 2,041.65 psi
    • 7050 tensile strength 77,600 psi
    • In this example, the clamping stress is only 2.6 % of the AL Alloy Tensile Strength
  • 12.
    • Will Aluminum Alloy handle high Injection pressure without failure?
    • Compressive strength of alloy – 77,600 psi
    • Maximum injection pressure at the front of
    • the screw (regardless of machine size) –
    • 33,000 psi
    • Percentage –33,000 / 77,600 = 42.5% of maximum at highest possible pressure
  • 13.  
  • 14.  
  • 15. The parts are removed at a lower temperature, resulting in less distortion and higher quality .
  • 16.  
  • 17. 7000 series welding improvements are being investigated.
  • 18. Recommendations                                       P20 / S55C Steel                                   4130 / sd18 Soft Steel                                   7000 Series Aluminum Alloy                                   M1 & & 7000 Hybrid                                   M1 Cast                                 100,000 500,000 1,000,000 1,500,000 2,000,000 2,500,000 3,000,000 Approximate Number of shots
  • 19.
    • Investment savings through machining efficiencies.
    • Process savings through improved thermal conductivity. (cycle time)
    • Reduce number of molds and injection machines required to mold the parts.
    • Different grades of aluminum can be applied based on Program volume.
    • Lower injection and clamp pressure required as compared to tool steel.
    • Plastic parts released from the molds at lower temperatures, resulting in less product distortion.
    Toll Free # 800-826-3370
  • 20. Thank You! Toll Free # 800-826-3370 We would like to Thank Honda of America Mfg., Inc. for allowing us to utilize their data to continue to educate the Aluminum Injection Mold Industry.