3 Year Aluminum Tooling Study Power Point Presentation


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3 Year Aluminum Tooling Study Power Point Presentation

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