RA1 – Part and Tool design

Knowledge Based Engineering – KBE

This RA is centred on the development of new tool concepts, with new technical solutions as well as new engineering postulates. The tooling industry is currently a highly empirical sector where knowledge is accumulated principally through industrial experience. The main aim here is to use new Knowledge Based Engineering technologies, to develop a generalised work methodology that systemises the acquisition and application of knowledge.

Thermal & Process Management – TPM

The objective is to develop applicable knowledge considering the tool as a machine of high complexity. This machine has to control intrinsic aspects of the injection process as well as the positions of the different mechanisms. It is vital develop new sensor concepts, that are cheaper and easier to incorporate. Likewise, an in-mould computerised process control system is still essential for the tool to work in a closed loop.

RA2 – Tool Manufacturing

Generative Processes

Layer manufacturing techniques are ideal for the automated production of complex moulds and ensure direct integration of functional features at little additional cost. The aim of this RA is to improve precision, surface finish, productivity and mechanical properties and to develop adequate manufacturing strategies for hybrid moulds (combining generative and subtractive manufacturing techniques).

Subtractive Processes

Advanced EDM milling has real potential to complement EDM (Electro Discharge Machining) in the fabrication of small mould details and in optimising the surface quality of hard steel. This potential is quantified and assessed in this RA to foster its implementation in the mould making industry.

RA3 – Extended Services

New Business Models

Business strategies and business models are developed in this RA to integrate services, comprising design engineering, guarantee of tool/mould availability, recycling and re-use. The focus is to extend the tool/mould making value chain vertically to include product design and product manufacturing and horizontally to encompass high-value, mould-related services.

Intelligent Tools

An intelligent tool concept is being developed and implemented. It is required in order to integrate sensorised systems within the mould/tool and to develop specific monitoring, diagnosis and control systems, which will allow remote process monitoring/control.

Life Cycle Analysis, Repair, Re-use and Recycling Strategies

The objective is to develop mould Life Cycle Analysis as a basis for improved design solutions, appropriate to the anticipated mould life. Another objective is to develop new ways to repair tools/moulds during their life cycle and to value the moulds at the end of their market life.

Mobile Engineering

Due to the lack of simple and integrated design and simulation tools which would permit the communication and visualisation of design modifications, a lot of time is still spent on making engineering decisions in geographically distributed teams. This research field is developing processes and infrastructures for collaborative work, in terms of both interpersonal and technical coherence.

Workflow in EuroTooling 21

The Research Areas (RA) cover the tool life cycle from design to extended services. The research is carried out in order to provide technology solutions to the specific issues in connection with each of the Case Studies.
In these Case Studies, SME tooling companies and the users of the mould or tool develop test cases for future tools and parts in strategic applications.
Subsequently the improvements are measured by a benchmarking process.
Dissemination and training activities eventually transfer the validated results to interested com- panies.

Current surface finishing and texturing technologies require labour intensive operations or electrochemical techniques, both of which are associated with high cost and environmental impact. To improve this situation, a combination of laser and milling technologies with adequate CAM software is being developed.

Innovative Technologies Development

In this RA, a cast-to-form tooling process is used for surface finishing and large moulds manufacturing. A process chain involving laser ablation generative part finishing, semi-automated cast part measurement and CAM file generation is under development. The fully automated process chain will subsequently be evaluated.

The Contour Crafting System (CCS) permits large components to be produced at high speed, using a variety of materials. The RA is promoting CCS usability to produce large tools, leading in the long-term to a completely integrated process, comprising material, machine and software.

The most promising option for economical mass production of micro-structured parts and systems, is to downscale the conventional processes currently used to machine ferrous, ceramic and carbide tools. The aim is to upgrade micro cutting, micro milling with cemented carbide tools, micro-sink-EDM and micro-wire-EDM in industrial process chains.

Innovative Materials

Ceramic material inserts in moulds for mass production significantly increase tool durability and reliability. The objective of this RA is to provide the knowledge required in order to use and machine these materials efficiently.