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Rapid Prototyping and Tooling of Automotive Seal Mouldings / IESTYN EVANS

Swansea University Author: IESTYN EVANS

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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 pro...

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Published: Swansea 2021
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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first_indexed 2021-12-08T16:55:16Z
last_indexed 2021-12-09T04:17:29Z
id cronfa58979
recordtype RisThesis
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spelling v2 58979 2021-12-08 Rapid Prototyping and Tooling of Automotive Seal Mouldings e8f8456d00aa16a4c19bfcdb01573290 IESTYN EVANS IESTYN EVANS true false 2021-12-08 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. E-Thesis Swansea Additive layer manufacturing, 3D printing, Injection moulding tooling 8 12 2021 2021-12-08 A selection of third party content is redacted or is partially redacted from this thesis due to copyright restrictions. COLLEGE NANME COLLEGE CODE Swansea University Rees, Andrew Master of Research MSc by Research M2A EPSRC funded with industrial partner Aston Martin M2A EPSRC funded with industrial partner Aston Martin. 2024-04-22T10:57:39.6854073 2021-12-08T16:50:31.8590285 Faculty of Science and Engineering School of Engineering and Applied Sciences - Uncategorised IESTYN EVANS 1 58979__21849__15b3d3db66424a0f8066cbf5f441f12b.pdf Evans_Iestyn_MSc_by_Research_Thesis_Final_Embargoed_Redacted.pdf 2021-12-08T17:06:05.7895866 Output 9477051 application/pdf Redacted version - open access true 2023-06-18T00:00:00.0000000 Copyright: The author, Iestyn Evans, 2020. true eng
title Rapid Prototyping and Tooling of Automotive Seal Mouldings
spellingShingle Rapid Prototyping and Tooling of Automotive Seal Mouldings
IESTYN EVANS
title_short Rapid Prototyping and Tooling of Automotive Seal Mouldings
title_full Rapid Prototyping and Tooling of Automotive Seal Mouldings
title_fullStr Rapid Prototyping and Tooling of Automotive Seal Mouldings
title_full_unstemmed Rapid Prototyping and Tooling of Automotive Seal Mouldings
title_sort Rapid Prototyping and Tooling of Automotive Seal Mouldings
author_id_str_mv e8f8456d00aa16a4c19bfcdb01573290
author_id_fullname_str_mv e8f8456d00aa16a4c19bfcdb01573290_***_IESTYN EVANS
author IESTYN EVANS
author2 IESTYN EVANS
format E-Thesis
publishDate 2021
institution Swansea University
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Uncategorised{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Uncategorised
document_store_str 1
active_str 0
description 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.
published_date 2021-12-08T10:57:37Z
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score 11.035655

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