Abstract
A technology of rapid tooling based on rapid prototype through the combination of electroforming with arc spraying can ensure the precision of mould primely, shorten the mold-making period and reduce cost. It came into being a way of rapid tooling.
Rapid prototypes are mostly nonmetallic prototypes, but electroforming requires that prototypes must be conductivity. So nonmetallic prototypes must be metallization. Through experiments of metallization of LOM paper prototype by brush-applied coating, arc spraying and electroless plating, the characteristics of them were gotten in this paper.
Though electroformed molds are very precise, electroforming time is long. And the quality of electrochemical deposit layer is influenced by many factors. In this paper, the experiment of technics factors of electroformed copper was carried out. The main factor and the optimum parameters to archive the best properties of the electroformed layer of cooper were obtained.
Based on electroforming layer, wire-arc spraying was used to thicken the metal shell and turn out molds rapidly. The arc-sprayed layer of high melting point metals on the slick surface of deposit layer may be deformed and break off. So it usually needs to roughen the surface to improve the bonding strength. But the coarseness was not used in this paper. The technique of arc spraying zinc in advance and then arc spraying copper was put forward to solve the problem of bonding strength.
In this paper, the experiment of technology factors of arc spraying zinc and arc spraying copper was carried through. The main factor and the reasonable parameters to gain the best qualityof arc-sprayed layer of zinc and copper were acquired.
In order to validate conclusions of experiments above, the injection mold of the foglight cover of truck EQ140-2 and the foam mold of oil pump body for lost foam were fabricated by electroforming and wire-arc spraying. Using these molds, plastic parts and foam patterns were produced. The result indicated that the technology of rapid tooling through the combination of electroforming with arc spraying is more economical and timesaving than the traditional machining and electroforming.
Key words:rapid toolin,electroforming,arc spraying,LOM,electroless plating
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