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This
application deals with a novel integrated solution for the design
and manufacture of a wide range of tooling. It will spearhead
South Africa's entry as a product based nation into the world
economy.
The
Closed Loop Automated Manufacturing (CLAM) technology is a further
refinement on the already successful Cast-To-Form capability
developed by the consortium leader Rapid Design Technologies (Pty)
Ltd. CLAM will revolutionise the manufacture of both pilot and
production tooling, leading to major time and cost savings for
clients.
The
consortium consists of both the Mechanical and Electrical
Engineering faculties of Witwatersrand University, Northern
Gauteng Technikon, Intracast Precision Foundry and a wide base of
sub contractors including the National Laser Centre and Laser
Optronic Technologies.
The
system is based on cast-to-form hollow back tooling in a closed
loop environment. It will be possible to manufacture tooling
across most conversion technologies including injection moulding
and pressure die-castings without the laborious conventional metal
hogging process. The solution involves investment casting the tool
components directly from a 3D Systems stereolithography pattern
slightly oversize, imaging the casting, then laser ablation or
high speed machining to tolerance. Unique textures are a distinct
possibility in the die, as part of the process.
The
consortium will revolutionise the man machine CAD interface by
integrating the latest touch enabled computer modelling system
developed by Sensable Technologies of the USA. This will
facilitate design intent without the designer having to compromise
design through the normal interface of keyboard and mouse,
traditionally with CAD systems. CLAM will, however, also integrate
with current CAD software through the STL file format. The
designer, reminiscent of the conventional pattern makers license
of old, can electronically carve subtle design metaphors utilizing
this interface.
The
project will also look at cultural design and the new method of
touch enabled computer modelling will be adapted for non CAD
literate designers.
This will
mean that designs can be electronically sculptured through a force
feedback device and further electronically manipulated right
through to tooling.
A
national network for tooling is envisaged that will make our
tooling industry competitive through the cluster approach ,as is
the norm in developed countries. This will lead to major job
creation in the whole product development, tooling and
manufacturing sectors.
The
benefits of the CLAM process include:
1.
Reduced tooling lead-times
2. Faster conversion speeds through fully optimised cooling
geometry (i.e. lower component cost)
3. Possibility of superior alloy choice for the tools. This
includes hot working steels for die casting applications
4. Unique textures on the tool surface including computer
generated patterns
5. Unique design with designer "hand print" which
traditional CAD systems have stifled through a designer unfriendly
interface
6. Rapid low cost pilot tooling in aluminium
7. Scalability requiring little additional time for multi-cavity
tooling
8. The possibility of manufacturing thinner walled components. By
optimising the cooling channels and getting cooling closer to the
mould operating surface components can be selectively chilled with
greater efficiency. This is the panacea that designers have
striven for to reduce the mass of components.
The
consortium will be working closely with industry players and the
intention is to benchmark the CLAM process on selected projects. |