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Direkte generative Fertigung von Schmiedegesenken eröffnet neue Möglichkeiten

: Müller, B.; Neugebauer, Reimund

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RTejournal - Forum für Rapid Technologie. Online journal (2010), Nr.7
ISSN: 1614-0923
Zeitschriftenaufsatz, Elektronische Publikation
Fraunhofer IWU ()
generatives Fertigungsverfahren; Laserstrahlschmelzen; rapid prototyping; Rapid Tooling; rapid manufacturing; Gesenkschmieden; Schmiedeprototyp; additive manufacturing; selective laser melting; rapid prototyping; Die Forging; forging prototype

Forming dies are a new and not yet explored application of additive manufacturing of tooling components ("rapid tooling"). The presentation shows a case study in which a typical forging of quite complex geometry could successfully be produced using a layer-manufactured forging die. Market demands for earliest possible availability of "real" forgings will be described. The complete process chain from 3D CAD tooling design through forging process simulation, selective laser melting of the die inserts, die assembly up to the actual forging trials under series-like conditions will be demonstrated und compared to conventional forging die design and manufacturing. Advantages and characteristics of the additive process chain will be pointed out. The manufactured forgings will be compared to conventionally forged parts in respect of die filling, dimensional accuracy and microstructure. Lead time of additively manufactured forging dies will be set in contrast to that of conventionally manufactured ones, as well as total cost to point out the advantages of applying additive manufacturing technology for rapid tooling purposes. Constraints for technologically and economically reasonable additive manufacturing of forging dies will be specified.