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2026
Conference Paper
Title
Topology and Cooling-Channel Optimization of Additively Manufactured Hot Sheet Metal Forming Tools Considering Thermo-Mechanical Process Loads
Abstract
Effective thermal management of hot sheet metal forming (HSMF) tools significantly impacts part quality, cycle time, and energy consumption. However, conventional cooling-channel manufacturing methods, such as drilling, often limit channel placement and hinder heat extraction near the tool surface. Additive manufacturing (AM) can overcome these limitations. Considering thermomechanical loads and manufacturing limitations, combining topology optimization (TO) with additive manufacturing, such as laser powder bed fusion (LPBF), enables the production of lightweight, highly efficient tools.
This work extends a validated load extraction and transfer workflow to enable AM-ready cooling-channel design and TO for an additively manufactured punch segment of a B-pillar base tool. LPBF manufacturing constraints (minimum wall thickness, overhang limits, and depowdering requirements) are explicitly considered. Cooling concepts are assessed by transient conjugate heat transfer simulations and verified by thermo-mechanical analysis.
The optimized segment, made of maraging steel 1.2709, was manufactured using a multi-laser LPBF machine and tested under representative HSMF conditions. The final design achieved a 26.4 % mass reduction while maintaining structural integrity. Operational simulations and experiments demonstrate more efficient and more even temperature distribution than conventionally cooled reference regions. This is evidenced by reduced hydraulic losses, lower and more uniform surface temperatures, higher initial cooling rates and reduced hardness scatter in the formed part. This improved thermal uniformity enables robust part hardening and reduces quenching time (cycle time) under industrial conditions.
This work extends a validated load extraction and transfer workflow to enable AM-ready cooling-channel design and TO for an additively manufactured punch segment of a B-pillar base tool. LPBF manufacturing constraints (minimum wall thickness, overhang limits, and depowdering requirements) are explicitly considered. Cooling concepts are assessed by transient conjugate heat transfer simulations and verified by thermo-mechanical analysis.
The optimized segment, made of maraging steel 1.2709, was manufactured using a multi-laser LPBF machine and tested under representative HSMF conditions. The final design achieved a 26.4 % mass reduction while maintaining structural integrity. Operational simulations and experiments demonstrate more efficient and more even temperature distribution than conventionally cooled reference regions. This is evidenced by reduced hydraulic losses, lower and more uniform surface temperatures, higher initial cooling rates and reduced hardness scatter in the formed part. This improved thermal uniformity enables robust part hardening and reduces quenching time (cycle time) under industrial conditions.
Author(s)