METHOD FOR MANUFACTURING TOOLING

Abstract

A method for manufacturing tooling includes forming a shape, forming a metallic plate over the shape, forming a structure over the metallic plate, and removing material from the metallic plate for obtaining the final tooling. The method permits material saving, as less scrap is produced and there is more flexibility in tooling design and manufacturing, and fast reactions to late design modifications.

Claims

1. A method for manufacturing tooling, comprising: forming a shape; forming a metallic plate over the shape; forming a structure over the metallic plate; and removing material from the metallic plate for obtaining the final tooling.

2. The method according to claim 1, wherein the forming of the shape is made by additive layer manufacturing.

3. The method according to claim 1, wherein the shape is made from a resin.

4. The method according to claim 3, wherein the resin is a polyurethane resin.

5. The method according to claim 1, wherein the metallic plate is formed by spraying a metallic coating over the shape.

6. The method according to claim 5, wherein the spraying comprises applying an electric arc between metal wires, so that the metal melts, and afterwards the metal is solidified blowing air.

7. The method according to claim 1, wherein the structure is formed by wire-arc additive manufacturing.

8. The method according to claim 1, wherein removing the material from the metallic plate comprises milling or mechanizing the metallic plate.

9. The method according to claim 1, comprising a simulation step before forming the structure.

10. The method according to claim 9, wherein the simulation step comprises simulating a thermal and deposition strategy.

11. The method according to claim 1, comprising releasing thermal stresses in the structure after forming the structure.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] For a better understanding the above explanation and for the sole purpose of providing an example, a non-limiting drawing is included that schematically depicts a practical embodiment.

[0035] FIG. 1 is a diagrammatical drawing of the steps of the method according to the disclosure herein.

DETAILED DESCRIPTION

[0036] The disclosure herein refers to a method for manufacturing large tooling combining conventional subtractive techniques with additive technologies ALM (Additive Layer Manufacturing) based on WAAM (Wire-Arc Additive Manufacturing).

[0037] This WAAM technique consists of the combination of a metallic material in wire format and an electric arc as a heat source.

[0038] Other metallic deposition techniques could be used to brow the metallic plate, like laser cladding, metal spraying, electro beam, etc.

[0039] The hybrid approach to manufacture tooling combines the use of addition and subtraction technologies.

[0040] An example of tooling that is manufactured with the method according to the disclosure herein is tooling that is used in aircrafts with carbon fiber reinforced polymer (CFRP) components.

[0041] According to a non-limitative preferred embodiment, the manufacturing method of the disclosure herein comprises the following steps:

[0042] Firstly, a resin, such as a polyurethane resin, is used to form a shape of the tooling. The material of the shape is deposited by additive manufacturing technology, such as Additive Layer Manufacturing (ALM).

[0043] Then a metallic coating is formed, e.g. by spraying, over the surface of the shape to form the plate of the tooling. This technique is similar to wire arc welding and consists of two raw metal wires that are ducted to an application gun and an electric arc is produced between both of them to make the material melt.

[0044] Then, a pressure air force is forced to blow out the metal melted and drops it against the shape surface. Melted material deposited cools down and solidifies again, generating the metallic coating.

[0045] A solid plate of more than 20 mm can be deposited suitable for machining or milling in the last step of the process and to achieve a good surface finish and good geometric tolerances, as will be described hereinafter.

[0046] A thermal and deposition strategy simulation is preferably performed to minimize thermal deformation during layers deposition.

[0047] Then, a structure of the tooling is formed, e.g. by Wire-Arch Additive Manufacturing (WAAM), on the metallic plate. Cords of metallic material are deposited, with certain strategy, to form the structure, being able to build complex geometries.

[0048] Before the final milling is necessary a step to release thermal stresses in the structure.

[0049] Finally, the metallic plate is milled or mechanized to achieve the superficial quality and tolerances required for the manufacturing.

[0050] Even though reference has been made to a specific embodiment of the disclosure herein, it is obvious for a person skilled in the art that the method described herein is susceptible to numerous variations and modifications, and that all of the details mentioned can be substituted for other technically equivalent ones without departing from the scope of protection defined by the attached claims.

[0051] While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms comprise or comprising do not exclude other elements or steps, the terms a, an or one do not exclude a plural number, and the term or means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims.