Abstract
AbstractA method of rapid electroforming tooling for the production of metal tools including molds, dies, and electrical discharge machining electrodes is developed. Geometry and material of the solid freeform fabricated part, properties of the electroformed metal, and process parameters are significant factors that cause inaccuracy in the manufactured tools. Thermomechanical modeling and numerical simulation are used to simulate thermal stresses induced during the burnout process that removes the rapid prototyping part from the electroform. The analysis demonstrates that appropriate design of the rapid prototyping part geometry and selection of electroform thickness not only reduce thermal stress, thus improving tooling accuracy, but also minimize manufacturing time and cost.
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