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
Your Session has timed out. Please sign back in to continue.


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.
Nakagawa, T., Kunieda, M., and Liu, S. D., 1985, “Laser Cut Sheet Laminated Forming Dies by Diffusion Bonding,” Proceedings of the 25th International 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, 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.
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), Issue 2910, Nov. 1996, pp. 198–209.
Himmer,  T., Nakagawa,  T., and Anzai,  M., 1999, “Lamination of Metal Sheets,” Comput Ind., 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, Vol. 5, No. 4, pp. 1–4.
Brown, K., “Implementation of the Profiled Edge Lamination Tooling Process Through Case Studies,” M.S. thesis, Dept. of Mechanical Engineering, Rensselaer Polytechnic Institute, 2002.
Dickens,  P. M., 1997, “Principles of Design for Laminated Tooling,” Int. J. Prod. Res., 35, pp. 1349–1357.
Crandall, S. H., Dahl, N. C., and Lardner, T. J., 1978, An Introduction to the Mechanics of Solids, 2nd ed., McGraw-Hill, New York.
Blau, P. J., 1996, Friction Science and Technology, Marcel Dekker, Inc., New York.
Standley, R., 2000, “Design and Analysis of Adhesively Bonded Laminated Tooling,” M.S. thesis, Dept. of Mechanical, Aerospace, & Nuclear Engineering, Rensselaer Polytechnic Institute.
Loctite adhesive datasheet, 2002, http://www.loctite.com/datasheets/tds/Product_312.pdf.
MatWeb Materials Property Database, http://www.matweb.com/, Automation Creations, Inc., Copyright 1997–2002.
ASTM D1002-01—Standard Test Method for Apparent Shear Strength of Single-Lap-Joint Adhesively Bonded Metal Specimens by Tension Loading (Metal-to-Metal).
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.
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.


Grahic Jump Location
Schematics of (a) an unclamped Profiled-Edge Laminae (PEL) tool, (b) an individual lamina, and (c) a clamped PEL tool
Grahic Jump Location
Flowchart for the PEL tooling development and fabrication process
Grahic Jump Location
Schematic showing the structural behavior for a PEL tool. Clamped laminations will be modeled as cantilevers
Grahic Jump Location
(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
Grahic Jump Location
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
Grahic Jump Location
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.
Grahic Jump Location
(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
Grahic Jump Location
Model of a single cantilevered lamination subjected to oppositely directed shear forces due to an adhesive bonding layer
Grahic Jump Location
Test set-up used for validating PEL tool structural models
Grahic Jump Location
(a) Schematic and (b) picture of experimental test set-up used for structural model validation
Grahic Jump Location
Schematic of the lap shear specimen used to obtain Ga
Grahic Jump Location
Deflection plots from structural FEM analyses for (a) Cases 1 and (b) Case 3
Grahic Jump Location
FEM model deflection plot for adhesively bonded laminations with Ga=8.2 MPa



Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In