Sheet metal forming dies constructed of laminations offer advantages over more conventional tooling fabrication methods (e.g. CNC-machining) in terms of tooling accessibility, reduced limitations on die geometry and faster fabrication with harder die materials. Furthermore, the recently introduced Profiled Edge Lamination (PEL) tooling method improves upon other lamination-based tooling methods. Adoption of this promising rapid tooling method by industry is being hindered by the lack of formal analysis, design principles, and manufacturing requirements needed to construct dies in such a manner. Therefore, the propensity for delamination of the die is discussed and preventive measures are suggested. The basic machining instructions, i.e., an array of points and directional vectors for each lamination, are outlined for both compound and planar profiled-edge bevels. Laser, AWJ and flute-edge endmilling are experimentally identified as the most promising methods for machining bevels. Development of a stand-alone PEL fabrication machine is suggested over retrofitting commercially-available 5-axis machines. Finally, the general procedure for creating PEL dies is implemented in the construction of a matched set of sheet metal forming tools. These tools are used to successfully stamp a sheet metal part out of draw-quality steel.
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November 1998
Research Papers
Rapid Tooling for Sheet Metal Forming Using Profiled Edge Laminations—Design Principles and Demonstration
D. F. Walczyk,
D. F. Walczyk
Dept. of Mechanical Engineering, Aeronautical Engineering & Mechanics, Rensselaer Polytechnic Institute, Troy, New York 12180-3590
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D. E. Hardt
D. E. Hardt
Laboratory for Manufacturing and Productivity, Massachusetts Institute of Technology, Cambridge, Massachusetts 02139
Search for other works by this author on:
D. F. Walczyk
Dept. of Mechanical Engineering, Aeronautical Engineering & Mechanics, Rensselaer Polytechnic Institute, Troy, New York 12180-3590
D. E. Hardt
Laboratory for Manufacturing and Productivity, Massachusetts Institute of Technology, Cambridge, Massachusetts 02139
J. Manuf. Sci. Eng. Nov 1998, 120(4): 746-754 (9 pages)
Published Online: November 1, 1998
Article history
Received:
November 1, 1996
Revised:
August 1, 1997
Online:
January 23, 2008
Citation
Walczyk, D. F., and Hardt, D. E. (November 1, 1998). "Rapid Tooling for Sheet Metal Forming Using Profiled Edge Laminations—Design Principles and Demonstration." ASME. J. Manuf. Sci. Eng. November 1998; 120(4): 746–754. https://doi.org/10.1115/1.2830215
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