https://popups.uliege.be/esaform21/index.php?id=3899 Publications of Auteurs Daniele Tomasoni fr 0 https://popups.uliege.be/esaform21/index.php?id=3972 In milling operations, the weight of the milling tool greatly affects the motion speed of the mandrel, especially when a complex tool path must be performed. Thus, it is essential to realize more lightweight tools, without a significant decrease in the mechanical and production performance. Traditionally, due to the limitation of the conventional manufacturing processes, the design of a new milling tool cannot be too much complex and thus cannot fully satisfy the mentioned goals. Nowadays, thanks to the topology optimization technique and the additive manufacturing (AM) technologies, such as the selective laser melting (SLM), it is possible to realize more complex part geometries to obtain more lightweight and high-performance tools. In this paper, a new design of a milling tool with a weight reduced by 30% is presented; SLM process has been selected to realize the milling tool. In order to minimize the use of support structures, required by the SLM process to correctly realize the desired part, the new geometry has been little modified. A more lightweight milling tool has been produced and every support structure has been successfully removed from the component. Tue, 30 Mar 2021 09:22:16 +0200 Mon, 12 Apr 2021 11:24:59 +0200 https://popups.uliege.be/esaform21/index.php?id=3972 https://popups.uliege.be/esaform21/index.php?id=3894 With the advent of 3D printing, it is now possible to produce any part or system with an approach than makes design much deeply interlaced with production. In this scenario, CAE has gained power thanks to the possibility of thinking and then manufacture ideas that go well beyond what was possible in the past. This design approach is perfectly suitable to push forward mould conformal cooling performance. In this work, a coupling of CAD, CFD and 3D printing supported by experimental tests was applied to define a design procedure for conformal cooling channels. In particular, cooling channels for a mould were engineered via CAD, then tested via CFD and, after an initial optimization procedure, the chosen design was 3D printed in specimens suitable to be mounted on a heat exchanger (HX) experimental test rig that was especially adapted for the scope. Fluids temperature, volume flow rates and heat transfer performance were measured. A feedback loop was considered to link measurements and channels redesign. Results together with design and testing procedures are reported and commented. Mon, 29 Mar 2021 14:56:38 +0200 Thu, 08 Apr 2021 21:24:50 +0200 https://popups.uliege.be/esaform21/index.php?id=3894