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TheRapidPrototypingManufacturinganditsapplicationinmoldingmanufacturingAbstractBydiscussingtherapidprototypingtechnologythecraftprinciple,characteristicoftheprocesses,formationandthegeneralsituationofthedevelopoffastprototypeanditsapplicationinmolding,pointoutthetechniquecanformakindofaprocesssystemofextensiveapplicationandnovel,anditsforegroundisvast.KeyKKKWordsrapidprototypingtechnologymoldingmanufacturingdevelopmentofproductRapidprototypingtechnologyisanewtypeofmultidisciplinaryintegratedmanufacturingtechnology.Afterthe1980s,followingtheapplicationofcomputeraideddesign,productshapeanddesigncapabilitieshavegreatlyimproved,however,productdesignhascompleted,production,asystemmustbedesignedtoconveytheconceptofsamples,rapidfeedbacktoproductdesign,productdesignandassessthefeasibility,andfeasibilitystudies.Theincreasinglyfiercecompetitioninthemarkettoday,thetimeiseffective.Toenhancethecompetitivenessofproducts,fromproductdevelopmenttovolumeproductionofthewholeprocessareurgentlyrequiredtoreducecostsandincreasespeed.Rapidprototypetechnologyappearanceprovidesaneffectivesolutiontothisproblemwhichmuchattentionathomeandabroad.1.ThebasicprincipleofRapidPrototypingTechnologyTheRPisthegenericnameoftheprinciplecreationproductprototypethatusesthelonglostlayering,itsprincipleisProduceCADmodel�Stratifiedseparated�accordingtotheplangeometryinformationwhichisdispersedtopileuptheoriginalmaterial�generatingentitymodels.Thistechnologyintegratesofcomputertechnology,laserprocessingtechnology,newmaterialtechnology,relyingonCADsoftwareinthecreationof3Dcomputermodelsentities,andisdividedintoaseriesofplanegeometryinformationtocontrolthescanninglaserbeamdirectionandspeed,usingsinter,poolingorchemicalreactionmeansexhaustiveselectiveprocessingofrawmaterials,thusrapidaccumulationmanufactureproductsentitiesmodels.2.ThecharacteristicsofRapidPrototypingTechnologyRapidPrototypingTechnologybreaksthetraditionalwaytoproducesparepartsofroughcast�slicetoparetoprocess�finished,Needlesscutlerycreatedthefirstproductionofspareparts,isanunprecedentedlaminareducingprocessingmethods.Comparingtotradition,thefastprototypeprocessesthefollowingadvantage1Producethesparepartsofthecurvedfaceandmorecomplicatedappearancequickly,suchasshoulderwithinsparepartsandhollowandpartsofetc.s,consumedlyloweredthedevelopmentcostofthenewproductanddevelopmentperiod.2Isanoncontactprocessing,machinetoolcuttingprocessingisnecessarycutleryandjigwithoutcutlerywearandcuttingforce.3Withoutvibration,noiseandslicetoparethewaste.4Cancarryoutthenighttimeoverfullautomaticproduction.5Processwithhighefficiency,producesthearticleentitymodelandmoldingtoolsquickly.TheformfollowsthecomparisonofthemethodfortheRapidPrototypingTechnologyandtradition.ComparisontheitemProcessingtechnologyThetoolmachineslicestoparetoprocessRPLightshapemethodprocessThemethodofprocessDoawaywiththesurplusmaterialprocessFoldthelayerprocessTheobjectofprocessSolidLiquid,portrait,powderToolThetoolofslicetopareLightbeamMinimumprocessingunitsDotsdiameterisabout1μmsTrianglesof200μmslongProductionofsparepartsTheleastprocessescometogetherthebodyoftheunitTheleastprocessescometogetherthebodyoftheunitTheRPandtraditionsslicetoparethemethodcomparisonsheet3.ThedevelopofRPRapidprototypingtechnologyconceptthattheconceptRPRapidPrototypingTechnologycouldbebackto1979.theprofessofZhongChuanWeixionginproduceandtechniqueinstituteofJapaneseUniversityofTokyoinventthemethodoffoldthelayermodel,theXiaoYuXiunanputforwardthelightshapemethodagainin1980,aftertheconceiveputforward,itwascontinuedtostudyin1984byWanGuYanger,andcarriedontoproducemanufactureonatrialbasisin1987.1988,theUnitedStatesrapidlyprototype3DSystemsCorporationwasthefirsttointroducepracticaldeviceslaserthreedimensionalshapesthatSLAStereoLightgraphyApparatus,andannualsalesgrowthrate3040increaseintheworldmarket.Inrecentyears,withincreasingperformancescanningamirror,andthedevelopmentofmaterialsscienceandcomputertechnology,rapidprototypingtechnologymatures,andin1994topromoteuniversalaccesstotheformalstage.Inaccordancewiththepatternsandmaterialsusedinthedifferenttypesofrapidprototypingtechnologycurrentlyhasthefollowingfourtypes.3.1SolidificationresinmaterialsusinglaserlightshapeslawThelightshapeequipmentisexcellentwithaproductofthe3DSystemscompanyoftheUnitedStates,andtheformationofamonopoly.Figure1showstheoperatingprinciples.Issuedbythelaserlight,theopticalsystemtocompileintoasmallbeam,thebeaminthecomputercontrolled,selectivescanningresinsurface,usinganultravioletresinFrozenmechanisms,alayerofsolidificationresin,eachlayerofsolidification,precisionworkstationsinadistancewiththenewlayerofsurfacegeometricinformationtothelaserscannerforscanningreading,solidificationofthenewlayerofresinandfirmlysticktothepreviouslayerhassolidificationresin,sorepeatedlyuntiltheproductionofsparepartsentitiesgeneratedamodel.Thelaserstereoscopicshapemanufacturingaccuracycanreachthe±0.1mms,mainlyusedtoprovidethesampleandtheexperimentmodelsfortheproduct.Inaddition,theSOLIFORMoftheJapanesesystemmachinedevelopedcanmanufacturetoinjecttomodelthemoldingtoolandvacuummoldingtoolsdirectly.Figure1Stereoscopiclightshapetechniqueprinciplediagram3.2ThepaperfoldsthelayershapemethodThepaperfoldstheLOMthatthelayershapemethoddevelopswiththeHelisyscompanycurrentlyapplicantmostwidely.Thedevicesusedforrollerpaperfromthepaperheatingrollercylindersconnectivity,andthenusingthelasertocutpaper,thequestionheatingrollercylindersautomaticallyleave,thepaperwillbereadybylaserlevelrequirementsintoshape,asshowninfigure2.Figure2PrinciplediagramofthepaperfoldsthelayershapeTheLOMcanmanufacturesomelargesparepartsandthethickwallkindpiecesofthehardcreationwithlightsshapemethodandcreatecostischeapaboutforthelightshapemethodof1/2,thespeedishighaboutmanufacturetimeforthewoodmoldofbelow1/5,andcansimplyanalyticthedesignconceiveoutlineandfunction.3.3meltdownshapemethodsThemeltdownshapemethodismostextensiveusedwiththeproductFDMwhichisdevelopedinAmericanStratasys,theFusedDepositionModeling,whenitisworking,theplasticsmaterialwithhotextrusionsprayeddirectlybysprinklerheadcontrolledbycomputercombinetolayertocreateanentitymodelfrombottomtotopaccordingtoseveralinformationoflevel.ThebiggestcharacteristicsinFDMtechnicalisaquickgeneralthemodelneedseveralhoursandcanimmediatelymodelandfreefrompollution,togettheextensiveapplicationinprototype,developandcastwaxmoleandsoon.3.4hotandfictileshapemethodsThehotandfictileshapemethodburnstheknotwiththeselectivitylaseroftheDTMcompanydevelopmentnamelytheSLStheSelectiveLaserSinteringapplicationisthemost.ThatmethodisawaymanufacturekindpiecethatburnswiththeCO2lasermachinecontrolsbythecalculator,carryonscanningonthematerialpowderaccordingtoseveralinformationforfacesofseveralpieceswithhorizontaleachlayerofthebody,thepowderisscanningbylaserandsolidifytogether.Then,spreadupanewpowderoflayer,thenscantoburntheknotwiththelaser,thusagainandagain,keeptogotomakethekindpiecewhichneeded.Asfigure3shows.Figure3TheprinciplechartofselectivitylasersinteringTheSLStechniqueshapespeedisfastgeneralware,needoneortwodaystocomplete,theshapeaccuracyishightheminimumthicknessofeachlayerpowderisabout0.07mms,thelaserdynamicstateaccuracycanreachthe±0.09mms,andhavetheautomaticlaserrepairfunction,theprototypestrengthishighgatheritsbentstrengthofthecarbonicacidfatandcanamounttothe34.5MPa,thenyloncanreach55MPa,therefore,cancarryonfunctionsexperimentandassembletheemulationwiththeprototype,toobtainthebestcurvedfacetomatchwiththeobservationthecondition.DevelopandappliedaspecttechnicallyinRP,theUnitedStatesandJapansarethebest.InHuazhongUniversitydevelopstwokindsofmodelsystemmachineHRPandRPSswhichisresearchtomanufacturein1994successfulquickly,havealreadyenteredthecommoditymarketcurrently,beappliedintheprofessionsextensively,suchasautomobile,toy,aviationaerospace,shipbuildingandthesoldierworketc.4.TheapplicationoftheRPinmoldingmanufacture4.1MakingthemoldfoundryfastPutthesparepartCADmodelconversetofastmethod,producemetalsparepartsquicklyaccordingtoeachlayershapeoffacetoforceramicmoldandthenaccordtofastmethod.Inaddition,cancarryouttheoriginalmoldthatthefastprototypetechniquemanufacturesaconductandactionsfoundermoldingtool,sparepartsoffastcast,itsprocessisDesignthesparepartsCAD3D�thecalculationhydrodynamicsanalysisCFD�theLOMmodelmanufacturing�castthemetalsspareparts.4.2fastmoldingtoolmanufacturingThetraditionalmoldingtoolmanufacturingmethodperiodislong,thecostishigh,asetofsimpleplasticsmoldingtoolisworthabove100,000dollars.Anyerrorofdesignreflectsthemoldingtoolmakethelossthatcantberetrieved.Fastprototypetechniquecanaheartandbodiesoftheaccuratemanufacturemoldingtool,alsocanusedforinjectingprocesstoproducemanufactureplasticspiecedirectly,forthepurposeofdetectionandthemistakethatrectifytoappear.ThecenterofnationalengineeringinAmericanIdahoandenvironmentsexperimentadoptthefastconcretioncraftnamelythetechniqueofRSPcarriedoutthefastandeconomyoftheplasticsmoldingmanufacture.Thatmethodadoptfastprototypetechnique
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