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High performance sheet metal forming tooling by additive manufacturing

Hochleistungs-Blechumform-Werkzeuge durch additive Fertigung
 
: Gebauer, Mathias; Müller, Bernhard; Spierings, Adriaan; Polster, Stefan; Stoll, Philipp; Feld, Tobias; Klinger, Marcel; Zurbrügg, Andreas

Drstvensek, Igor (Ed.) ; Rapid Prototyping and Innovative Manufacturing Network -RAPIMAN-:
6th International Conference on Additive Technologies, iCAT 2016. Proceedings : 29.-30. November 2016, Nürnberg
Ljubljana: Interesansa, 2016
ISBN: 978-961-285-537-6
S.354-361
International Conference on Additive Technologies (iCAT) <6, 2016, Nürnberg>
Englisch
Konferenzbeitrag
Fraunhofer IWU ()
laser beam melting; additive manufacturing; metal forming; tooling; dies and mould; simulation; sensor integration; lubrication; conformal cooling

Abstract
The additive manufacturing technology Laser Beam Melting (LBM) is an emerging technology that has the potential to change toolmaking. It allows manufacturing tools of almost any complexity with very little geometrical limitations, directly from 3D CAD data out of standard metal alloys, including hot-work steel (high-alloy tool steel). Additive manufacturing of tooling for plastic injection molding can already be described as state of the art. However, other tooling applications can potentially also benefit from the advantages of LBM.As part of a research project, the use of LBM for different sheet metal forming technologies is currently being investigated. Main objective of the project is the development of tooling inserts to significantly improve the metal forming process by reducing cycle time and scrap rate as well as improving the resulting part quality. These improvements are addressed by introducing novel features into metal forming tooling components, including innovative thermal management for heating and cooling, an in-process lubrication system and sensor integration for process monitoring, all using LBM as the technology of choice to enable these new features. The paper describes the developments undertaken to fulfill the objectives, and presents results from simulation and experiment to illustrate the related increase in tooling performance.

: http://publica.fraunhofer.de/dokumente/N-431973.html