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Why Aluminum Mold?

Why Aluminum Mold?. Toll Free # 800-826-3370. Increased Cycle Times. Aluminum has 5 times better heat transfer than P20 steel Aluminum has almost 6 times better heat transfer compared to H-13 Steel. Molders have experienced a 20% to 40% faster cycle time. . Toll Free # 800-826-3370.

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Why Aluminum Mold?

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  1. Why Aluminum Mold? Toll Free # 800-826-3370

  2. Increased Cycle Times • Aluminum has 5 times better heat transfer than P20 steel • Aluminum has almost 6 times better heat transfer compared to H-13 Steel. • Molders have experienced a 20% to 40% faster cycle time. Toll Free # 800-826-3370

  3. Lower cost on Mold Build • Aluminum Mold can be machined up to 30% faster overall with appropriate high speed CNC machines and cutting tools specifically designed for aluminum • Polishing time is reduced. • Aluminum is 1/3 the weight of steel. • Service Centers can ship aluminum within 1-3 days, versus steel. Toll Free # 800-826-3370

  4. Increase Quality of Parts • Aluminum alloys offer higher thermal conductivity, so the parts are removed at a lower temperature. This leads to better dimensional stability of parts providing higher yields on the molding process. Toll Free # 800-826-3370

  5. Aluminum Mold Grades5000 and 5083 • Cast product with three North American Producers • Available in North American up to 30" thick and 74" wide (only 20” thick at this width) • This alloy is for low volume or prototype molds. • No abrasive plastics • Drawbacks •         Heat transfer is slower due to the low copper content   / Cycle times are going to be slightly lower than other aluminums •         Hardness is low 70 HB •         yield and tensile strengths are lower than other aluminums available •         Because of the hardness a high polish is hard to achieve • Benefits •    Cost - Weight .96 dense •         because its a cast plate cost is much less than rolled or forged block •         Machinability is very good due to the lack of copper content •         stability is the best of any aluminum •         Has great weldability •         because copper content is low the corrosion resistance is very high •         sizes available •         through hardness Trade Names: Alpase – K100S & M 5 Vista – ATP-5 & Duramold 5 Toll Free # 800-826-3370

  6. Aluminum Mold Grades2618 • Cast product with two North American Producers • This alloy has higher yield and tensile strengths than 6061 with hardness very close to 6061 • can be used for low volume production and prototype tools • sizes available 38 thick 94 wide • Drawbacks •     Machinability (This is within the aluminums available / Still would machine much better than steel) Chips might stick to cutters gummy. •     hardness is low (again within the aluminums available) 82 to 90HB •     Polishability • Benefits •     Cost compared to 6061/ 7000 •     weldability •     heat transfer very high •     yield and tensile strength are high compared to 6061 •     sizes available •     through hardness Trade Names: Alpase – M1 Vista – Duramold 2 Toll Free # 800-826-3370

  7. Aluminum Mold Grades6061 • rolled plate • 16 thick • 84 wide • 192 long • Drawbacks •     Machinability is poor •     hardness 89 -96 HB •     Polishability • Benefits •     thermal transfer rate is high •     cost compared to 7000 series •     weldability Trade Names: Kaiser select Toll Free # 800-826-3370

  8. Aluminum Mold Grades7000 Series • Three available alloys besides 7075 • available 28” thick in forged block • Drawbacks •     Weldability /  Can be welded but you have to follow the welding instructions very carefully •     Stability - All 7000 series can move during machining if not stress relieved • Benefits •     BTu's are very high 88- 100 •     Machinability •     Yield and Tensile strengths are very high •     sizes available •     Hardness 150- 180 HB •     Polishability  A mirror finish is achievable Trade Names: Aleris – Hokotol Alcan – Alumold 7075 – General product Toll Free # 800-826-3370

  9. Honda – 3 year study Their approach for reviewing Aluminum Alloy 1. Met with key Aluminum Alloy Material Suppliers 2. Honda paid for 3rd Party Testing to validate Material composition, mechanical properties, abrasion resistance and compression strength. 3. Concluded that Honda should begin working with its suppliers to build Aluminum Alloy Tools. (ZQ/WQ) 4. Honda decided to build aluminum tools and pay for the backup Steel Tool Purpose: a. Review Clamping pressure b. Review injection pressure c. Evaluate Tool build efficiencies d. Evaluate Process Cycle time 5. Honda paid for Texture plaque development to further understand Aluminum Alloy texture capabilities as well as repair methods. 6. Monitor Tool Maintenance and durability concerns 7. Based on Low Volume Results, began focusing on High Volume applications to validate AL Alloy durability.

  10. Mechanical Testing

  11. Review - Clamping Pressure Can the mold be crushed by too much pressure? Unit stress = load/area Projection area of mold = 46 x74 = 3404 in2 Projection area of part = 955 in2 Contact area = 3404 - 955 = 2449 in2 Stress (2500 ton press) =5,000,000 / 2449 = 2,041.65 psi 7050 tensile strength 77,600 psi In this example, the clamping stress is only 2.6 % of the AL Alloy Tensile Strength

  12. Review - Injection Pressure. • Will Aluminum Alloy handle high Injection pressure without failure? • Compressive strength of alloy – 77,600 psi • Maximum injection pressure at the front of the screw (regardless of machine size) – 33,000 psi • Percentage –33,000 / 77,600 = 42.5% of maximum at highest possible pressure

  13. Tool Lead Time Comparison of Mold BuildsP20 Steel vs. Aluminum Alloy

  14. Review – Investment Cost

  15. Review - Cycle Time The parts are removed at a lower temperature, resulting in less distortion and higher quality .

  16. Review -Honda Texture Study

  17. Review - Welding 7000 series welding improvements are being investigated.

  18. Benefits of Aluminum Alloy • Investment savings through machining efficiencies. • Process savings through improved thermal conductivity. (cycle time) • Reduce number of molds and injection machines required to mold the parts. • Different grades of aluminum can be applied based on Program volume. • Lower injection and clamp pressure required as compared to tool steel. • Plastic parts released from the molds at lower temperatures, resulting in less product distortion. Toll Free # 800-826-3370

  19. Questions We would like to Thank Honda of America Mfg., Inc. for allowing us to utilize their data to continue to educate the Aluminum Injection Mold Industry. Thank You! Toll Free # 800-826-3370

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