Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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Application of additive manufactured tungsten carbide tool electrodes in EDM

2018 , Uhlmann, Eckart , Bergmann, André , Bolz, Robert , Gridin, Witalij

Application fields of electrical discharge machining (EDM) are limited due to given process conditions. When producing structures of high aspect ratios or using multi-axis machining, removed particles assemble at the machining zone, leading to process instabilities. A promising approach to improve EDM process conditions is the utilization of flushing channels in the tool electrode. However, with increasing complexity of the electrode geometry and the local integration of the mentioned flushing channels, conventional electrode manufacturing reaches its limitations. By applying Selective Laser Melting (SLM), these limitations are eliminated. The appropriate integration of flushing channels, even for complicated electrode geometries, improves process conditions during EDM in a variety of applications, leading to a higher material removal rate VW and reduced tool wear TH compared to machining without flushing. Additionally, the number of required tool electrodes can be reduced, as SLM enables an efficient integration and miniaturization of all features in a single electrode. Of particular interest in the field of EDM is carbide. Because of its wear resistance and stability, it is an ideal electrode material, which is commonly applied in mEDM. Tungsten carbide-cobalt is representative for this group of materials, which is already used in tool manufacturing. Several tests show a general suitability of carbide tool electrodes made by SLM for EDM-processing. However, the SLM process parameters and the composition of the carbide-cobalt show significant impact to the EDM results. A lower proportion of cobalt leads to reduced material removal rates VW and rising tool wear.

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Studie zur Verarbeitung von Wolframkarbid-Kobalt für die additive Fertigung von innenkonturierten Werkzeugen

2012 , Bergmann, André , Gridin, Witalij , Uhlmann, Eckart

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Contribution to a database of Ti-6Al-4V components manufactured with selective laser melting process

2017 , Uhlmann, Eckart , Bergmann, André , Gridin, Witalij , Rolon, Daniel Alexandre

In summary, the components manufactured additively through SLM proved to have characteristics similar to conventionally manufactured parts in high temperatures. Especially when testing the material properties with temperatures higher than 300 °C. This assumption is not only supported by a quantitative analysis of the material properties, but also by characterizing the microstructure of the SLM samples. Moreover, a database is constituted, which can help to design and plan components built using SLM through extensive simulations. Future works, should study the different possibilities of constructing the tensile test samples. Moreover, studies could focus on other types of super alloys such as Inconel 718, which is often employed in the same context as Ti-6Al-4V.

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Shortened manufacturing of individualized carbide tools by selective laser melting and hot isostatic pressing

2017 , Uhlmann, Eckart , Bergmann, André , Gridin, Witalij

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