Research On Performance And Process Of Aluminum-filled Epoxy Resin Rapid Tooling

As a rapid tooling, the Composite Aluminum-filled Epoxy rapid tooling has a strongtrend of development in the mode of modern manufacturing of small batch, multi-variety,and rapid modification. However, the domestic molding process and material performanceare still lag behind the international advanced level. As the development of themanufacturing industry goes on, there are higher requirements for material performanceand molding process. Aiming at optimizing material formulation and improving thequality of mold, researches on the material performance and molding process ofComposite Aluminum-filled Epoxy rapid tooling were carried out.The material formulation and molding process of Composite Aluminum-filled Epoxyrapid tooling were optimized in this paper. In the material aspect, the correspondingpouring solidification process was determined by single factor test on the basis of materialcomponents which is determined by the same test. The four factors and three levelsorthogonal experiment was designed and its results were analyzed by using range analysisand fracture morphology analysis; an excellent material formulation and the relationshipbetween microstructure and mechanical performance of the material were obtained, whichpaved the way for material performance analysis. In the mold design aspect, according tothe characteristics of the mold material pouring，the frame of adjustable size and thecorresponding formwork were designed, and the pouring system of injection molded partswas analyzed and designed by using Moldflow. The innovative idea of making pouringsystem, ejection system and master pouring and manufacturing at one time is proposed byexperiment, paraffining the pouring system and ejection system can make it easier to theremovement of master, reduce damage to the mold and the post processing timesignificantly. The closed-loop control principle of aluminum-filled epoxy mold injectionproducts errors is proposed via the systematic error research from the process of molddesign, production and injection process, improved the accuracy of mold injectionproducts.By adopting the research methods mentioned above, intensive studies on materialformulation and molding process of Aluminum-filled Epoxy Tooling were executed. Theresults turn out an excellent material formulation and its corresponding pouring processand systemic molding process. Especially in the molding process system, the method ofthe pouring system, ejection system and master manufacture and pouring at one time get a good result, which has certain reference value for metal resin rapid tooling technology andproved new method and ideas for it.