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TECHNICAL PAPERS

Structural Modeling of Profiled Edge Laminate (PEL) Tools Using the Finite Element Method

[+] Author and Article Information
Jeremy T. Shook, Daniel F. Walczyk

Department of Mechanical, Aerospace, & Nuclear Engineering, Jonsson Engineering Center, Rensselaer Polytechnic Institute, Troy, New York 12180-3590E-mail: walczd@rpi.edu

J. Manuf. Sci. Eng 126(1), 64-73 (Mar 18, 2004) (10 pages) doi:10.1115/1.1645874 History: Received September 01, 2003; Online March 18, 2004
Copyright © 2004 by ASME
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References

Walczyk, D. F., and Hardt, D. E., 1994, “A New Rapid Tooling Method for Sheet Metal Forming Dies,” Proceedings of the5thInternational Conference on Rapid Prototyping, Dayton, OH, pp. 275–289, June 12–15.
Walczyk,  D. F., and Hardt,  D. E., 1998, “Rapid Tooling for Sheet Metal Forming Using Profiled Edge Laminations—Design Principles and Demonstration,” ASME J. Manuf. Sci. Eng., 120, pp. 746–754, November.
Walczyk, D. F., and Hardt, D. E., 1996, “Recent Developments in Profiled-Edge Lamination Dies for Sheet Metal Forming,” Proceedings of Solid Freeform Fabrication Conference, The University of Texas at Austin, pp. 215–226, August.
Im,  Y. T., and Walczyk,  D. F., 2002, “Development of a Computer-Aided Manufacturing System for Profiled Edge Lamination Tooling,” ASME J. Manuf. Sci. Eng., 124(3), August, pp. 754–761.
Im, Y-T., 2001, “The Development of a Rapid Tooling System for Profiled Edge Lamination Dies and Molds,” Ph.D. Thesis, Dept. of Mechanical, Aeronautical and Nuclear Engineering, Rensselaer Polytechnic Institute of Technology, April.
Hart, F. V., 1942, “Mold and Mold Making Method,” U.S. Patent No. 2274060, Issued Feb. 24.
Nakagawa, T., Kunieda, M., and Liu, S. D., 1985, “Laser Cut Sheet Laminated Forming Dies by Diffusion Bonding,” Proceedings of the25thInternational Machine Tool Design and Research Conference, Dept. of Mechanical Engineering, University of Birmingham, England, April 24–25, pp. 505–510.
Glozer,  G. R., and Brevick,  J. R., 1993, “Laminated tooling for injection molding,” Proc. Inst. Mech. Eng., 207(1), pp. 9–14.
Soar,  R., and Dickens,  P. M., 1996, “Design of Laminated Tooling for High Pressure Die Casting,” Proceedings of the SPIE (International Society for Optical Engineering) Conference, Boston, MA, Issue 2910, Nov. 1996, pp. 198–209.
Himmer,  T., Nakagawa,  T., and Anzai,  M., 1999, “Lamination of Metal Sheets,” Computers in Industry, 39, pp. 27–39.
Dormal,  T., and Baraldi,  U., 1999, “New Technology for Manufacturing Large Prototype Injection Molds: Laminated Laser Cut Cavities,” SME Rapid Prototyping Newsletter, 5(4), pp. 1–4.
Brown, K., 2002, “Implementation of the Profiled Edge Lamination Tooling Process Through Case Studies,” M.S. Thesis, Dept. of Mechanical Engineering, Rensselaer Polytechnic Institute.
Dickens,  P. M., 1997, “Principles of Design for Laminated Tooling,” Int. J. Prod. Res., 35(5), May, pp. 1349–1357.
Bickford, W. B., 1993, Mechanics of Solids: Concepts and Applications, R. D. Irwin, Inc., Burr Ridge, IL.
Shook, J. T., 2000, “The Development of a General Finite Element Modeling Method for Profiled Edge Laminated Tools,” Master’s Thesis, Dept. of Mechanical, Aeronautical, and Nuclear Engineering, Rensselaer Polytechnic Institute of Technology, Troy, NY, May.
Pepelnjak, T., Kampus, Z., and Kuzman, K., 1996, “Layered Tool Structure for Improved Flexibility of Metal Forming Processes,” Advanced Manufacturing Systems and Technology, CISM Courses and Lectures No. 372, Springer Verlag, New York, pp. 339–346.

Figures

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Schematics of (a) an unclamped Profiled-Edge Laminate (PEL) tool, (b) possible features of an individual laminate clamped in a fixture, and (c) a completely clamped PEL tool
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Flowchart for the PEL Tooling Development and Fabrication Process
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Schematic showing the general structural behavior of a PEL tool
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Components of a Structural Load on a PEL Tool Loading
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Differences in FEM gap element creation
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Increase in effective lateral stiffness of FEM model due to the introduction of gap elements
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Schematic of an adhesively bonded PEL tool
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PEL tool structural test setup
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CAD Model (side view) of PEL test tool used for FEM analysis
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Free Body Diagram of Hinged Pressure Plate
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Traction Forces Applied on PEL Test Tool
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Simplified FEM model of aluminum PEL test tool mounted in a stiff steel cradle
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Displacement Contours for Structural Clamped Model
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Displacement Contours for Structural Bonded Model
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Example of a 3-D PEL tool used for hydroforming

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