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TECHNICAL PAPERS

Structural Modeling of Profiled Edge Laminae (PEL) Tools

[+] Author and Article Information
Daniel F. Walczyk, Yong-Tai Im

Department of Mechanical, Aerospace, & Nuclear Engineering, Rensselaer Polytechnic Institute, 110 8th Street, Troy, NY 12180-3590

J. Manuf. Sci. Eng 127(1), 138-147 (Mar 21, 2005) (10 pages) doi:10.1115/1.1826074 History: Received February 17, 2003; Revised April 27, 2004; Online March 21, 2005
Copyright © 2005 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 the 5th International Conference on Rapid Prototyping, Dayton, OH, June 12–15, pp. 275–289.
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.
Armillotta, A., Monno, M., and Moroni, G., 1998, “Rapid Waterjet,” Jetting Technology (BHR Group), pp. 59–71.
Im,  Y. T., and Walczyk,  D. F., “Development of a Computer-Aided Manufacturing System for Profiled Edge Lamination Tooling,” ASME J. Manuf. Sci. Eng., 124, pp. 754–761.
Hart, F. V., 1942, “Mold and Mold Making Method,” U.S. Patent No. 2274060, issued Feb. 24.
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Glozer, G. R., and Brevick, 1993, “Laminated Tooling for Injection Molding,” Proceedings of the Institution of Mechanical Engineers; Part B: Journal of Engineering Manufacture, Vol. 207, No. 1, pp. 9–14.
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Brown, K., “Implementation of the Profiled Edge Lamination Tooling Process Through Case Studies,” M.S. thesis, Dept. of Mechanical Engineering, Rensselaer Polytechnic Institute, 2002.
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Standley, R., 2000, “Design and Analysis of Adhesively Bonded Laminated Tooling,” M.S. thesis, Dept. of Mechanical, Aerospace, & Nuclear Engineering, Rensselaer Polytechnic Institute.
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ASTM D1002-01—Standard Test Method for Apparent Shear Strength of Single-Lap-Joint Adhesively Bonded Metal Specimens by Tension Loading (Metal-to-Metal).
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Shook,  J. T., and Walczyk,  D. F., 2004, “Structural Modeling of Profiled Edge Lamination (PEL) Tooling using the Finite Element Method,” ASME J. Manuf. Sci. Eng., 126, pp. 64–73.

Figures

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Schematics of (a) an unclamped Profiled-Edge Laminae (PEL) tool, (b) an individual lamina, and (c) a clamped PEL tool
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Flowchart for the PEL tooling development and fabrication process
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Schematic showing the structural behavior for a PEL tool. Clamped laminations will be modeled as cantilevers
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(a) 2-D sideview of a PEL tool modeled as n layered laminations subjected to a lateral forming load F, which experiences a lateral deflection δ, and (b) 3-D geometry of a single lamina
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Individual structural models of n laminae in a PEL array subjected to lateral load F , interlaminar frictional loads, and normal loads concentrated at the lamina tip
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Individual structural models of n laminae in a PEL array subjected to lateral load F, interlaminar frictional loads, and normal loads distributed as a ramp function along the entire length of lamina. Note that laminae are not shown in their deflected states.
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(a) Schematic of adhesively bonded PEL tool, and (b) shear deflection 𝛁 of the adhesive bond between assumed “rigid” laminae, and the geometry for estimating this deflection
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Model of a single cantilevered lamination subjected to oppositely directed shear forces due to an adhesive bonding layer
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Test set-up used for validating PEL tool structural models
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(a) Schematic and (b) picture of experimental test set-up used for structural model validation
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Schematic of the lap shear specimen used to obtain Ga
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Deflection plots from structural FEM analyses for (a) Cases 1 and (b) Case 3
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FEM model deflection plot for adhesively bonded laminations with Ga=8.2 MPa

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