In contrast to SL based rapid tooling approaches, high speed machining is an alternative process for manufacturing intricate prototype parts using injection molding. This project will investigate the machinability characteristics of Vantico (Ciba-Geigy) tooling board materials, specifically the CIBA-Express ceramic-filled epoxy tooling board materials. In past work, aluminum filling materials were investigated for the machining characteristics. Since these materials can machine faster than aluminum, they hold tremendous promise for rapid tooling applications where speed is critical.
Prof. Shreyes Melkote is leading this project, supervising graduate student Tosin Tomori. Broadly speaking, the goal of the project is to develop a fundamental understanding of the surface integrity of machined ceramic-filled epoxy tooling board and the impact on injection mold performance. Experimental objectives include the investigation of the effects of filler material and concentration on machinability, machining conditions on surface integrity as a function of filler material, and surface integrity on mold performance. To date, much of the experimentation has been completed. Results indicate the following: machining forces increase with increasing % filler, surface roughness increases with increasing % filler, and machining reduces the material’s ultimate compressive strength. Most results were expected, but had not been as thoroughly quantified. A tool wear study and an evaluation of machined mold performance must still be completed.
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