AMM

23
4 7 2552

Prototype of a Rapid Tooling Machine by Laminated Object Manufacturing

1*, 1,2

1
10900
2

10900
(668) 41302726 0-2579-4576
*E-mail: kim7777@gmail.com

(Rapid Prototyping RP) RP


( Rapid Tooling RT)













: , , Laminated Object Manufacturing (LOM)
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Abstract
In today industries, manufacturers require techniques that can help designers in designing and
manufacturing parts. Prototypes are made in order to help in decision making. Part appearance, ability for
assembly, and function can be checked before the mass production begins. Mechanical tests can be
conducted in order to check several mechanical aspects of the parts. Rapid prototyping (RP) is the only
available choice in today manufacturing industries. However, RP machine is quite expensive. Material
used for making the prototypes is very expensive since only the RP manufacturers know the composition
and properties of the materials mostly plastic. Moreover, these plastic prototypes made by the
conventional RP machines are not function parts. That means they cannot be tested for assembly.
Mechanical tests are inappropriate to be conducted as well. Introduced in this paper, Rapid tooling (RT)
by using layer manufacturing technique is a new choice for the manufacturers. Our Rapid Tooling
Machine by Layered Manufacturing utilizes sheet materials that are easy to find and affordable. Sticky
material likes glue is used to hold the sheets together. Three-D file of the part that we want to make the
prototype is fed to the computer. After that, the 3-D file of the associated mold is created and sliced along
the Z-axis. Sheets are cut using the machine according to the slice information from the previous step.
The thickness of the sheets is the layer height while stacking up the sheets layer by layer starting from
the bottom to the top. While stacking up the sheets one by one, hot plate is brought in every layer in
order to heat the glue or the sticky material beneath the sheets. After the stacking process has been
finished, mold is ready to be used for casting the part using the appropriate material. In this paper, the
paper sheets are used because of the price. The principles can, however, apply to the metal sheets or
sheets made by other materials.
Keywords: Layer Manufacturing, Rapid Tooling, Laminated Object Manufacturing (LOM).

1.





(CAD)
3 (Solid Model)




(Concept)
(Function
Testing)
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2.

.. 2521
.. 2531
RP


Rapid Tooling (RT) [1-3]




RP

[4] RT
RP RT 2.1
2.1.1.
[5]
Laminated
Object Manufacturing (LOM) RP
RT
(Layering Technique) LOM 2.1.2.
RT
CAD 3 Milling ( CNC)

LOM
[6], 2.1.3.
(Rapid Prototyping Machine)
, 3
[7-9],
Layering
Technique Solid
model STL file
(1 )
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CNC Milling


()
2 Laminated Object Manufacturing (LOM)
()

()

1 () Solid Model,
() STL file, () Sliced Layers 3 LOM

2.1.4.



(Soft
Molding) (Sand Casting)
WAX Investment Casting
4 LOM
2.2 Laminated Object Manufacturing (LOM)
LOM( 2) 2.3 (Rapid Tooling)
Helisys









( 3 4 )
LOM


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CAD
( 6)

1. (Pneumatic)
0.5 9.9
2.4 2.
160 x 160 x 12 . 80 x 170 x
40 .2
LOM (Laminated 3.
300 x 400 x 8 .2
Object Manufacturing)
40 x185 x 10 .
CAD 25 . 380 mm
4
4.
300 x 400 x 25 . 2
110 . 30 .
( 5) 50 . 50 .
5.
330 x 250 x 20 .
2 30 x 250 x 30 .
10 .

Rapid Tooling 4 16 .
200 .

6.
7. 20
8. 600 1
9. Thermocouple

3.
3.1 Rapid Tooling 6 CAD
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3.2
1. 1 Pentium Core 2 Duo
1.8 GHz., DDR-Ram 2 GB., Harddisk 160 GB.,
4.3.1 () DXF File
256 MB., 19
2. Laser Engraving 1 Laser
(7 (.)) Engraving
3. Rapid Tooling (3.1) 1 2

( 7(.)) 4.3

4.3.1 () Laser
Engraving

(.) (.) 4.3.3

4.3.2 ()
7 (.) Laser Engraving (.)
(Rapid Tooling)

Layer
4.

4.3.2 ()


4.1
3 4.1

4.4 ()
4.2.1



4.4
DXF File
4.2
4.4 ()

4.2.2 4.2.4 DXF
File
8

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4.1
3
Laser Scan

STL File
4.2 STL File Slice

4.2.1. Plane (.)

9 CAD
Plane
() 2
0.098 mm DXF () 3 ()

4.2.2.


swapxz X
Z DXF File
File DXF
10 X
X 30
Z Z
Code DXF
Save File DXF
(.)
4.2.3. File
Thousand

File DXF Layer
Layer
File File DXF

(.) Layer
DXF Code
Layer
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Code DXF File File 5.

4.2.4. File
Hole 4 DXF File
File DXF 1. 60 x 60 x
SEQEND Code Circle 15.84 .
DXF File 4 176 0.084 .
176 x 0.084 = 14.8 .
4.3 Rapid Tooling
4.3.1. Laser
Engraving File DXF 4.2
Laser Engraving

4.3.2.
2

160 11 1
10
4.3.3. 1 2
Rapid Tooling
(1 0)

12 (RT) 1

1 1


(.) (.) (.)
10 (%) (%) (%)
CAD 60.0 - 60 - 14.8 -
4.4
RT 59.8 0.3 59.7 0.5 14.7 0.8

59.6 0.7 59.6 0.7 14.7 0.8
4.3


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1 1
3 2
2 3
0.3 % 0.5 %
0.8 % 0.8 %
3 0.7 % 0.8 %
0.7% 0.8 %
2. 0.8 % 0.8 %
50 . 14.8
1 6.


LOM

Prototype


13 2 Prototype




Rapid Tooling


14 (RT) 2
Rapid Prototype
2 2 Rapid Tooling



(.) (.) Automatic Optimum
(%) (%)
CAD 50.0 - 14.8 -
RT 49.5 0.8 14.7 0.8
49.5 0.8 14.7 0.8

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