Testing single point incremental forming moulds for rotomoulding operations

Abstract

Low pressure polymer processes as thermoforming or rotational moulding use much simpler moulds than high pressure processes like injection. However, despite the low forces involved in the process, moulds manufacturing for these applications is still a very material, energy and time consuming operation. Particularly in rotational moulding there is no standard for the mould manufacture and very different techniques are applicable.The goal of this research is to develop and validate a method for manufacturing plastically formed sheet metal moulds by single point incremental forming (SPIF) for rotomoulding and rotocasting operations. A Stewart platform based SPIF machine allow the forming of thick metal sheets, granting the required structural stiffness for the mould surface, and keeping a short manufacture lead time and low thermal inertia. The experimental work involves the proposal of a hollow part, design and fabrication of a sheet metal mould using dieless incremental forming techniques and testing its o...