E-Thesis 486 views 39 downloads
Rapid Prototyping and Tooling of Automotive Seal Mouldings / IESTYN EVANS
Swansea University Author: IESTYN EVANS
Abstract
EPDM exterior automotive seals are currently only manufactured by injection mould-ing or extrusion, both requiring expensive tooling which are produced by traditional machining. Aston Martin and other automotive companies regularly need a small num-ber of seals to be produced, upwards of 100 for pro...
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Swansea
2021
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| Institution: | Swansea University |
| Degree level: | Master of Research |
| Degree name: | MSc by Research |
| Supervisor: | Rees, Andrew |
| URI: | https://cronfa.swan.ac.uk/Record/cronfa58979 |
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| Abstract: |
EPDM exterior automotive seals are currently only manufactured by injection mould-ing or extrusion, both requiring expensive tooling which are produced by traditional machining. Aston Martin and other automotive companies regularly need a small num-ber of seals to be produced, upwards of 100 for prototype testing and small production runs required for limited edition vehicle programs. This project looks at whether rapid prototyping techniques can be used to manufacture tooling for injection moulding of EPDM used for short production runs, reducing cost and lead time associated with tra-ditional machining.A novel rapid prototype tooling methodology is proposed which optimises rapid pro-totyping techniques, combining rapid tooling techniques of metal powder and epoxy. Mechanical and thermal properties of the proposed novel rapid prototype tooling are validated by computational simulation performed in ANSYS 19.1 software. An opti-mum rapid prototype tooling is deduced from displacement, stress, and thermal foot-print results.It has been shown through computational modelling that the proposed novel rapid tool-ing methodology produces a number of tooling that would be capable of small produc-tion runs of EPDM seals by injection moulding. 5mm thick titanium shell with rein-forcement is proposed as the optimum rapid prototype tooling which would be capable of producing upwards of 100 EPDM seals by injection moulding. A total cost saving of 210% could be made when utilising rapid prototyping techniques in the manufacture of tooling for injection moulding of EPDM. |
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| Item Description: |
A selection of third party content is redacted or is partially redacted from this thesis due to copyright restrictions. |
| Keywords: |
Additive layer manufacturing, 3D printing, Injection moulding tooling |
| College: |
Faculty of Science and Engineering |
| Funders: |
M2A EPSRC funded with industrial partner Aston Martin. |