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    Aluminum Tooling Study-Aluminum Mold Plate

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    mauricefjohnson
    The document discusses the benefits of using aluminum alloys for injection molds compared to steel. It provides information on the thermal conductivity and cycle time improvements experienced by molders when using aluminum. Specific aluminum alloys are also summarized, outlining their properties, advantages, and disadvantages for injection molding applications. Recommendations are made to use different aluminum alloys depending on part volume based on their suitability and cost effectiveness.

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    Attribution Non-Commercial (BY-NC)
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    Aluminum Tooling Study-Aluminum Mold Plate

    Uploaded by

    mauricefjohnson
    40 views20 pages
    The document discusses the benefits of using aluminum alloys for injection molds compared to steel. It provides information on the thermal conductivity and cycle time improvements experienced by molders when using aluminum. Specific aluminum alloys are also summarized, outlining their properties, advantages, and disadvantages for injection molding applications. Recommendations are made to use different aluminum alloys depending on part volume based on their suitability and cost effectiveness.

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    The document discusses the benefits of using aluminum alloys for injection molds compared to steel. It provides information on the thermal conductivity and cycle time improvements experienced by molders when using aluminum. Specific aluminum alloys are also summarized, outlining their properties, advantages, and disadvantages for injection molding applications. Recommendations are made to use different aluminum alloys depending on part volume based on their suitability and cost effectiveness.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    40 views20 pages

    Aluminum Tooling Study-Aluminum Mold Plate

    Uploaded by

    mauricefjohnson
    The document discusses the benefits of using aluminum alloys for injection molds compared to steel. It provides information on the thermal conductivity and cycle time improvements experienced by molders when using aluminum. Specific aluminum alloys are also summarized, outlining their properties, advantages, and disadvantages for injection molding applications. Recommendations are made to use different aluminum alloys depending on part volume based on their suitability and cost effectiveness.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 20

    Toll Free # 800-826-3370

     Aluminum has 5 times better heat transfer


    than P20 steel

     Aluminum has almost 6 times better heat


    transfer compared to H-13 Steel.

     Molders have experienced a 20% to 40%


    faster cycle time.

    Toll Free # 800-826-3370


     Aluminum Mold can be machined up to 30% faster
    overall with appropriate high speed CNC machines
    and cutting tools specifically designed for
    aluminum

     Polishing time is reduced.

     Aluminum is 1/3 the weight of steel.

    Service Centers can ship aluminum within


    1-3 days, versus steel.

    Toll Free # 800-826-3370


     Aluminum alloys offer higher thermal
    conductivity, so the parts are removed at a
    lower temperature. This leads to better
    dimensional stability of parts providing
    higher yields on the molding process.

    Toll Free # 800-826-3370


     Cast product with three North American Producers
     Available in North American up to 30" thick and 74" wide (only 20” thick at this width)
     This alloy is for low volume or prototype molds.
     No abrasive plastics
            
     Drawbacks
             Heat transfer is slower due to the low copper content   / Cycle times are going to be slightly lower
    than other aluminums
             Hardness is low 70 HB
             yield and tensile strengths are lower than other aluminums available
             Because of the hardness a high polish is hard to achieve
      
     Benefits
             Cost - Weight .96 dense
             because its a cast plate cost is much less than rolled or forged block
             Machinability is very good due to the lack of copper content
             stability is the best of any aluminum
             Has great weldability
             because copper content is low the corrosion resistance is very high
             sizes available
             through hardness

       Trade Names:
    Alpase – K100S & M 5
    Vista – ATP-5 & Duramold 5

    Toll Free # 800-826-3370


     Cast product with two North American Producers
     This alloy has higher yield and tensile strengths than 6061 with hardness very close to 6061
     can be used for low volume production and prototype tools
     sizes available 38 thick 94 wide
      
     Drawbacks
         Machinability (This is within the aluminums available / Still would machine much better than steel)
    Chips might stick to cutters gummy.
         hardness is low (again within the aluminums available) 82 to 90HB
         Polishability
      
     Benefits
         Cost compared to 6061/ 7000
         weldability
         heat transfer very high
         yield and tensile strength are high compared to 6061
         sizes available
         through hardness
    Trade Names:
    Alpase – M1
    Vista – Duramold 2

    Toll Free # 800-826-3370


                                   
     rolled plate

     16 thick

     84 wide

     192 long

      

     Drawbacks

         Machinability is poor

         hardness 89 -96 HB

         Polishability

     Benefits

         thermal transfer rate is high

         cost compared to 7000 series

         weldability

    Trade Names:
    Kaiser select

    Toll Free # 800-826-3370


     Three available alloys besides 7075
     available 28” thick in forged block
      
     Drawbacks
         Weldability /  Can be welded but you have to follow the welding instructions very
    carefully
         Stability - All 7000 series can move during machining if not stress relieved
      
     Benefits
         BTu's are very high 88- 100
         Machinability
         Yield and Tensile strengths are very high
         sizes available
         Hardness 150- 180 HB
         Polishability  A mirror finish is achievable Trade Names:
    Aleris – Hokotol
    Alcan – Alumold
    7075 – General product

    Toll Free # 800-826-3370


    Their approach for reviewing Aluminum Alloy

    1. Met with key Aluminum Alloy Material Suppliers

    2. Honda paid for 3rd Party Testing to validate Material composition,


    mechanical properties, abrasion resistance and compression strength.

    3. Concluded that Honda should begin working with its suppliers to build Aluminum Alloy Tools.
    (ZQ/WQ)
    4. Honda decided to build aluminum tools and pay for the backup Steel Tool
    Purpose: a. Review Clamping pressure
    b. Review injection pressure
    c. Evaluate Tool build efficiencies
    d. Evaluate Process Cycle time
    5. Honda paid for Texture plaque development to further understand Aluminum Alloy texture
    capabilities as well as repair methods.
    6. Monitor Tool Maintenance and durability concerns
    7. Based on Low Volume Results, began focusing on High Volume
    applications to validate AL Alloy durability.
    Can the mold be crushed by too much
    pressure?

    Unit stress = load/area


    Projection area of mold = 46 x74 = 3404 in2
    Projection area of part = 955 in2
    Contact area = 3404 - 955 = 2449 in2
    Stress (2500 ton press) =5,000,000 / 2449 =
    2,041.65 psi
    7050 tensile strength 77,600 psi
    In this example, the clamping stress is only 2.6 % of the
    AL Alloy Tensile Strength
     Will Aluminum Alloy handle high Injection pressure
    without failure?
     Compressive strength of alloy – 77,600 psi
     Maximum injection pressure at the front of
    the screw (regardless of machine size) –
    33,000 psi
     Percentage –33,000 / 77,600 = 42.5% of maximum
    at highest possible pressure
    The parts are
    removed at a lower
    temperature,
    resulting in less
    distortion and higher
    quality .
    7000 series welding improvements are
    being investigated.
    Recommendations
                       
                   

      P20 / S55C Steel                


                   
    4130 / sd18 Soft
      Steel                

                   
    7000 Series
      Aluminum Alloy                
                   
    M1 & & 7000
      Hybrid                
                   
      M1 Cast            
                       

    100,000 500,000 1,000,000 1,500,000 2,000,000 2,500,000 3,000,000

    Approximate Number of shots


    1. Investment savings through machining
    efficiencies.
    2. Process savings through improved thermal
    conductivity. (cycle time)
    3. Reduce number of molds and injection machines
    required to mold the parts.
    4. Different grades of aluminum can be applied
    based on Program volume.
    5. Lower injection and clamp pressure required as
    compared to tool steel.
    6. Plastic parts released from the molds at lower
    temperatures, resulting in less product distortion.

    Toll Free # 800-826-3370


    We would like to Thank Honda of
    America Mfg., Inc. for allowing us
    to utilize their data to continue to
    educate the Aluminum Injection
    Mold Industry.

    Thank You!

    Toll Free # 800-826-3370

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