Modern tool design for component grading incorporating simulation models, efficient tool cooling concepts and tool coating systems

Schieck, Frank; Hochmuth, C.; Polster, Stefan; Mosel, André

doi:10.1016/j.cirpj.2011.06.001

Cited by 17 publications

(8 citation statements)

References 4 publications

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“…Some authors [8,9] perform meticulous studies in order to determine the effect of main process parameters on the metallurgy of the parts. Additive Manufacturing offer a real solution when manufacturing conformal cooling channels with complex geometries and, therefore, advance towards rapid cooling [10].…”

Section: Introductionmentioning

confidence: 99%

Case Study to Illustrate the Potential of Conformal Cooling Channels for Hot Stamping Dies Manufactured Using Hybrid Process of Laser Metal Deposition (LMD) and Milling

Cortina

Arrizubieta

Calleja

et al. 2018

Metals

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Hot stamping dies include cooling channels to treat the formed sheet. The optimum cooling channels of dies and molds should adapt to the shape and surface of the dies, so that a homogeneous temperature distribution and cooling are guaranteed. Nevertheless, cooling ducts are conventionally manufactured by deep drilling, attaining straight channels unable to follow the geometry of the tool. Laser Metal Deposition (LMD) is an additive manufacturing technique capable of fabricating nearly free-form integrated cooling channels and therefore shape the so-called conformal cooling. The present work investigates the design and manufacturing of conformal cooling ducts, which are additively built up on hot work steel and then milled in order to attain the final part. Their mechanical performance and heat transfer capability has been evaluated, both experimentally and by means of thermal simulation. Finally, conformal cooling conduits are evaluated and compared to traditional straight channels. The results show that LMD is a proper technology for the generation of cooling ducts, opening the possibility to produce new geometries on dies and molds and, therefore, new products.

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Section: Introductionmentioning

confidence: 99%

Case Study to Illustrate the Potential of Conformal Cooling Channels for Hot Stamping Dies Manufactured Using Hybrid Process of Laser Metal Deposition (LMD) and Milling

Cortina

Arrizubieta

Calleja

et al. 2018

Metals

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show abstract

“…Strip drawing tests were conducted with a 90 • bending operation in order to ensure good metrological accessibility and also to illustrates the real forming conditions. When compared to the pin-on-disc test method and the conventional strip drawing, the applied BUT provides corresponding surface contact conditions for sheet metal forming [22,23]. A pump drives the drawing cylinder after starting the test, causing a tractive force on the strip and making it slide over the test tool.…”

Section: Friction Testsmentioning

confidence: 99%

Tribological Investigations on Tool Surfaces for Temperature-Supported Forming of Magnesium AZ31 Sheets

et al. 2020

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Aiming to decrease friction coefficient ( μ ) during the forming of magnesium alloy sheets, nine (9) tools with different hole geometries in their surface (flat, elliptical, and circular) were manufactured from steel Boehler W400 VMR (as known as DIN 1.2343). Tribological investigations were accomplished on a strip drawing machine at 288 °C without lubricants. When compared with a standard tool (surface flat), on average, tools with circular geometries in their surface showed the smallest friction coefficient, while tools with elliptical geometries shown higher. The friction coefficient also was confronted with the ratio between area occupied by holes in the surface of the tool and the total tool surface (i.e., factor f (%)), hole diameter (Ø), and the distance between circle centers (d(c,c)). Principal Component Analysis (PCA) complemented the experimental approach. In summary, both approaches (experimental and theoretical) indicated that the manufactured tool with circular geometries on its surface presented lower friction coefficient values on the forming processes of the magnesium AZ31 sheets.

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“…Forming tools often exhibit complex geometries and internal cooling channels, to grant fast cooling rates of the forming parts and reduce thermal gradients and thermal stresses inside the tool . The construction of complex‐shaped cooling systems located close to the tool surface is desired for optimized tool efficiency and part quality .…”

Section: Introductionmentioning

confidence: 99%

Processing of X65MoCrWV3‐2 Cold Work Tool Steel by Laser Powder Bed Fusion

Boes

Röttger

Theisen

2019

steel research int.

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Laser powder bed fusion (L-PBF) of forming tools has become of major interest in the tooling industry because of the high geometrical flexibility of this process. During L-PBF, a metallic powder bed is melted selectively by a laser beam, enabling the layer-wise manufacturing of parts from 3D computer-aided design data. The process is characterized by a locally and temporally unsteady heat flow in the solidified part and in the melt pool, causing nonequilibrium solidification and phase transformations. In addition, rapid heating and cooling occur, promoting the formation of microstructural defects, cold cracks, and distortion. Because of the high tendency to form cold cracks, processing of martensitic tool steels is still a challenging task. Tool steel X65MoCrWV3-2 is processed by L-PBF and the resulting microstructure and the associated local properties are investigated by microhardness measurements, nanoindentation, and scanning electron microscopy. It is gathered from the investigations that regions of different microstructures and mechanical properties on both micro-and macroscale are present in the L-PBF-densified steel. The different microstructures and properties are the result of the alternating heat insert at different temperature regimes, forming heat-affected zones in which the tempering processes are triggered and strongly varying properties are generated.

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Modern tool design for component grading incorporating simulation models, efficient tool cooling concepts and tool coating systems

Cited by 17 publications

References 4 publications

Case Study to Illustrate the Potential of Conformal Cooling Channels for Hot Stamping Dies Manufactured Using Hybrid Process of Laser Metal Deposition (LMD) and Milling

Case Study to Illustrate the Potential of Conformal Cooling Channels for Hot Stamping Dies Manufactured Using Hybrid Process of Laser Metal Deposition (LMD) and Milling

Tribological Investigations on Tool Surfaces for Temperature-Supported Forming of Magnesium AZ31 Sheets

Processing of X65MoCrWV3‐2 Cold Work Tool Steel by Laser Powder Bed Fusion

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