Aluminum mold for prepreg


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quinn
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I'm about to start machining my mold but I have a few concerns. The composite part is an 800m long tapered tube. 46mm diameter at one end, 30mm at other end. The closed mold is 75mm square by 800mm long. This means the mold walls will be as thin as 15mm at one end and as thick as 22mm at other end. One concern is the time it takes for this big chunk of aluminum to heat up, the other concern is uneven heating, thinner walled end heating up first. How should I approach this with my ramp cycles? Just go slower in general? Hold temps longer? I'm really not sure what to expect for how long it's gonna take for it to heat up. If the varying wall thickness is gonna be a big problem, I can do some machining on the outside to even it out, but would rather not if it isn't needed. First few parts will be done with vacuum bag so the laminate will be exposed to the heated air but later on I'll be trying silicone expanding plug so I'm sure that will change things as far as heating. Any advice on how to approach this? Thanks
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Steve Broad
Steve Broad
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quinn - 1/20/2019 4:05:44 PM
Steve Broad - 1/20/2019 9:30:05 AM
Photographic evidence? :-)
Here it is. The fan I got on Amazon for pretty cheap. It's a blower fan made for fireplaces so figured it's probably designed to handle some heat. Handled one cycle so far, we'll see if it holds up. Temp controller also on amazon for pretty cheap. I just had it set to a basic mode that holds one temp, but once I figure out the terrible chinglish manual, it can go through up to 12 difference temperature profiles with specific amounts of time. Should be great for a full ramp up, soak, ramp down cycle. The temp sensor on it is a bit slow to react though. That other little temp sensor I bought sitting next to the controller seems much better. I'll try moving the controllers sensor in front of fan air to see if it reads quicker. One thing that's bugging me a bit, the oven puts off a smell, not like burning, but I think it's from the mdf getting hot. Mdf combusts at like double my my max temp, so not worried about it, but hopefully the smell will get better after a couple cycles. Probably wouldn't notice it if I didn't open the door while running a cycle.

Edit: running into a slight issue. My oven is too efficient lol. Ran another cycle this morning with my aluminum molds in it. Ramp up of mold temp was slower but not too bad, with probe placed inside a bored hole in the mold, it took a bit over an hour to go from 20c to 120c. Ramping down is the issue. This mold stores some serious energy. Without the mold in there, the oven would drop a couple degrees per minute with bulbs off, with mold in there, it has now been over an hour since bulbs turned off and it has only dropped to 108c. The mold is like a big heating element in the oven and doesn't want to ramp down with the insulation containing all the energy in the oven. Easy solution would be to just open the door, but I'd like to have a full cycle of ramp up/ramp down programmed without having to touch the oven. My temp controller does have an outlet for cooling, just need to figure out what to power with it. Somehow need to set it up to vent the oven without losing insulation during ramp up. 


Looks very good. I wonder how long it will be before it is too small? :-)

quinn
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Steve Broad - 1/20/2019 11:41:33 PM
quinn - 1/20/2019 4:05:44 PM
Steve Broad - 1/20/2019 9:30:05 AM
Photographic evidence? :-)
Here it is. The fan I got on Amazon for pretty cheap. It's a blower fan made for fireplaces so figured it's probably designed to handle some heat. Handled one cycle so far, we'll see if it holds up. Temp controller also on amazon for pretty cheap. I just had it set to a basic mode that holds one temp, but once I figure out the terrible chinglish manual, it can go through up to 12 difference temperature profiles with specific amounts of time. Should be great for a full ramp up, soak, ramp down cycle. The temp sensor on it is a bit slow to react though. That other little temp sensor I bought sitting next to the controller seems much better. I'll try moving the controllers sensor in front of fan air to see if it reads quicker. One thing that's bugging me a bit, the oven puts off a smell, not like burning, but I think it's from the mdf getting hot. Mdf combusts at like double my my max temp, so not worried about it, but hopefully the smell will get better after a couple cycles. Probably wouldn't notice it if I didn't open the door while running a cycle.

Edit: running into a slight issue. My oven is too efficient lol. Ran another cycle this morning with my aluminum molds in it. Ramp up of mold temp was slower but not too bad, with probe placed inside a bored hole in the mold, it took a bit over an hour to go from 20c to 120c. Ramping down is the issue. This mold stores some serious energy. Without the mold in there, the oven would drop a couple degrees per minute with bulbs off, with mold in there, it has now been over an hour since bulbs turned off and it has only dropped to 108c. The mold is like a big heating element in the oven and doesn't want to ramp down with the insulation containing all the energy in the oven. Easy solution would be to just open the door, but I'd like to have a full cycle of ramp up/ramp down programmed without having to touch the oven. My temp controller does have an outlet for cooling, just need to figure out what to power with it. Somehow need to set it up to vent the oven without losing insulation during ramp up. 


Looks very good. I wonder how long it will be before it is too small? :-)

Had the same thought so I designed it much bigger than I had originally planned. Before i was only gonna make it big enough for the boom mold, but decided I might eventually do cf sheets or canopies. Interior is 950mm wide, 450mm deep, 500mm high (350mm from floor to bulbs). Plenty big for any future projects I would do. 

GO

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