Hostname: page-component-6898cfcb55-w5hgh Total loading time: 0 Render date: 2026-11-11T12:21:33.702Z Has data issue: false hasContentIssue false
  • English
  • Français

Rapid Electroforming Tooling

Published online by Cambridge University Press:  10 February 2011

Bo Yang and
Ming C. Leu
Bo Yang
Affiliation:
Department of Mechanical Engineering, New Jersey Institute of Technology, Newark, NJ 07102, yangbo@pb.com
Ming C. Leu
Affiliation:
Department of Mechanical and Aerospace Engineering and Engineering Mechanics, University of Missouri-Rolla, Rolla, MO 65409
Get access

Abstract

A method of rapid electroforming tooling for the production of metal tools including molds, dies, and electrical discharge machining electrodes is developed. Geometry and material of the solid freeform fabricated part, properties of the electroformed metal, and process parameters are significant factors that cause inaccuracy in the manufactured tools. Thermomechanical modeling and numerical simulation are used to simulate thermal stresses induced during the burnout process that removes the rapid prototyping part from the electroform. The analysis demonstrates that appropriate design of the rapid prototyping part geometry and selection of electroform thickness not only reduce thermal stress, thus improving tooling accuracy, but also minimize manufacturing time and cost.

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

Article purchase

Temporarily unavailable

References

1 Spiro, P., 1968, Electroforming, Robert Draper Ltd.Google Scholar
2 Yang, B., Leu, M. C., 1999, Integration of Rapid Prototyping and Eletroforming for Tooling Application. Annals of the CIRP, 48/1.Google Scholar
3 Yang, B., Leu, M. C., 2000, EDM Tooling by Electrodeposition of Rapid Prototyping Parts. International Journal of Agile Manufacturing, Vol. 5.Google Scholar
4 Safranek, W. H., 1986, The Properties of Electrodeposited Metals and Alloys. Second edition, American Electroplaters and Surface Finishers Society, Orlando, Florida.Google Scholar
5 Degarmo, E.P., Black, J.T., Kohser, R.A., 1984, Materials and Processes in Manufacturing, Sixth edition, Macmillan Publishing Company, New York.Google Scholar
6 Kruth, J.-P., Leu, M. C., Nakagawa, N., 1998, Progress in Additive Manufacturing and Rapid Prototyping, Annals of the CIRP, 47/2.Google Scholar
7 Leu, M.C., Zhang, W., 1998, Research and Development of Rapid Prototyping and Tooling in the United States, Proc. of First International Conference on Rapid Prototyping and Manufacturing, Beijing, China.Google Scholar
8 Jacobs, P.F., 1997, Recent Advances in Rapid Tooling from Stereolithography, Proc. of the Seventh International Conference on Rapid Prototyping, San Francisco.Google Scholar
9 Sachs, E., Cima, M., Cornie, J., 1990, Three-Dimensional Printing: Rapid Tooling and Prototyping Directly from a CAD Model, Annals of the CIRP, 39/1.Google Scholar
10 Bourell, D.L., Crawford, R.H., Marcus, H.L., Beaman, J.J., Barlow, J.W., 1994, Selective Laser Sintering of Metals, J. of Manufacturing Science and Engineering, 68/2.Google Scholar
11 Yang, B., 2000, Rapid Tooling by Integration of Solid Freeform Fabrication and Electrodeposition, Ph.D. Dissertation, New Jersey Institute of Technology.Google Scholar
12 Leu, M.C., Yang, B., Yao, W.L., 1998, A Feasibility Study of EDM Tooling Using Metalized Stereolithography Models. Technical Papers of NAMRC, XXVI, Atlanta.Google Scholar
13 Stein, B., 1996, A Practical Guide to Understanding, Measuring and Controlling Stress in Electroformed Metals, Proc. of AESF Electroforming Symposium, Las Vegas.Google Scholar
14 Duffy, J. I., 1980, Electroless and Other Non-Electrolytic Plating Techniques, Noyes Data Corporation, New Jersey.Google Scholar
15 Yang, B., Leu, M.C., 1999, Rapid Production of Engineering Tools and Hollow Bodies by Integration of Electroforming and Solid Freeform Fabrication, US patent application filed.Google Scholar
16 Boley, B. A., Weiner, J. H., 1960, Theory of Thermal Stresses, John Wiley &Sons, New York.Google Scholar