Profiled Edge Laminae (PEL) tooling is a thick-layer Rapid Tooling (RT) method that was developed a decade ago. Even with demonstrable advantages for large-scale tool applications over conventional CNC-machining of a solid billet and other commercially available RT methods, PEL tooling has not seen widespread use by industry because prior research related to laminated tooling has (1) focused on small-scale tools and perpendicular laser-cutting that required extensive surface finishing, and (2) there is no integrated and practical design and fabrication approach to tooling development. This paper describes a more streamlined and integrated approach to PEL tooling development, called the PEL Process, that builds upon prior work in this area. Critical components of the process that are described in detail include how to obtain lamina slicing information directly from a CAD model of the intended tool surface, how to measure dimensional errors between the PEL and CAD tool surfaces, and improved Abrasive Waterjet cutting trajectory and laminae slicing algorithms. The PEL Process is then demonstrated for the design and fabrication of aluminum PEL tooling used for hydroforming aircraft sheet metal components.
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ASME 2005 International Mechanical Engineering Congress and Exposition
November 5–11, 2005
Orlando, Florida, USA
Conference Sponsors:
- Manufacturing Engineering Division and Materials Handling Division
ISBN:
0-7918-4223-1
PROCEEDINGS PAPER
A New Integrated Design and Fabrication Process for Profiled Edge Laminae (PEL) Tooling
Daniel F. Walczyk,
Daniel F. Walczyk
Rensselaer Polytechnic Institute
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Seungryeol Yoo
Seungryeol Yoo
Rensselaer Polytechnic Institute
Search for other works by this author on:
Daniel F. Walczyk
Rensselaer Polytechnic Institute
Seungryeol Yoo
Rensselaer Polytechnic Institute
Paper No:
IMECE2005-79274, pp. 247-258; 12 pages
Published Online:
February 5, 2008
Citation
Walczyk, DF, & Yoo, S. "A New Integrated Design and Fabrication Process for Profiled Edge Laminae (PEL) Tooling." Proceedings of the ASME 2005 International Mechanical Engineering Congress and Exposition. Manufacturing Engineering and Materials Handling, Parts A and B. Orlando, Florida, USA. November 5–11, 2005. pp. 247-258. ASME. https://doi.org/10.1115/IMECE2005-79274
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