Research on the redesign of precision tools and their manufacturing process based on selective laser melting (SLM)

Abstract

Purpose – This paper aims to verify that additive manufacturing technology could be used for the redesign and rapid manufacturing of tools and determine whether the mechanical performance of such tools can satisfy the practical operating requirements. Design/methodology/approach – A special key was selected as the research object in this paper. The special key was innovatively redesigned and manufactured directly using selective laser melting (SLM). The function and critical geometries of the special key were first analysed, which was followed by discussions on the geometrical constraints in the manufacturing of typical geometrical features using SLM technology. Next, the special key was redesigned based on the SLM geometrical constraints and the functional requirements. Finally, the key was manufactured using SLM, and the mechanical performance characteristics of the key were determined. Findings – The minimal geometrical feature was 0.2 mm when manufacturing thin walls using SLM. The reliable building angle of an overhanging surface was 40°. The top surface quality of the part could be greatly improved through laser surface re-melting. The volume of the redesigned special key based on the SLM process was only one-third to one-fourth of the original key. The mechanical properties, such as tensile strength and micro-hardness, of the samples manufactured using SLM were able to reach the practical operating requirements. Originality/value – It is completely feasible to redesign and manufacture precision tools based on the innovative approach of SLM. The advantages of the redesigned tools includes the lack of design restrictions that hinder traditional manufacturing methods, material savings, ability to produce tools that cannot be easily copied and rapid production speed for a small number of tools.

Acoustic Metamaterials: A Review of Theories, Structures, Fabrication Approaches, and Applications

“…Additive manufacturing, more commonly known as 3D printing, is an advanced manufacturing technology that has progressed rapidly in recent years and is now being widely used in numerous fields. Several additive manufacturing methods that build objects layer by layer, including laminated object manufacturing, [ 116 ] fused deposition modeling (FDM), [ 117 ] selective laser melting (SLM), [ 118 ] selective laser sintering (SLS), [ 119 ] stereolithography (SLA), [ 120 ] and electron beam melting (EBM), [ 121 ] have been developed. The emergence of additive manufacturing has greatly facilitated the development and practical application of AMs.…”

“…[106] Copyright 2018, AIP Publishing. www.advmattechnol.de methods that build objects layer by layer, including laminated object manufacturing, [116] fused deposition modeling (FDM), [117] selective laser melting (SLM), [118] selective laser sintering (SLS), [119] stereolithography (SLA), [120] and electron beam melting (EBM), [121] have been developed. The emergence of additive manufacturing has greatly facilitated the development and practical application of AMs.…”

Additive manufacturing applied to injection moulding: technical and economic impact

“…Within the AM domain, selective laser melting (SLM) is one of the most important processes on additive manufacturing technology nowadays, where metallic powder is processed layer-by-layer, by one or more lasers. The process consists on the total fusion of the metal powder, resulting on near 100 per cent solid parts with almost no compromise concerning mechanical properties (Wang et al , 2016; Gao et al , 2015; Frazier, 2014). This additive manufacturing process is a technology in which the final product shows similar characteristics to the materials used in the mould making industry, enabling its use for the manufacture of mould inserts incorporating complex cooling channels.…”

Study on Topology Optimization Design, Manufacturability, and Performance Evaluation of Ti-6Al-4V Porous Structures Fabricated by Selective Laser Melting (SLM)

“…Although SLM technology extends its manufacturing limit to the geometry with tiny intern cavities and holes, the geometry with overhangs at the angle of 30° to the horizontal cannot be manufactured because of not enough support from underlayer powder during the SLM process, which should be investigated firstly because of its difference in materials, geometries and type of SLM machine. Many researchers [ 10 , 11 , 12 , 13 ] have discussed the manufacturability of metallic parts using SLM under their special investigation condition. Di Wang exhibited the results for manufacturing limits of parts from 316L stainless steel with different geometrical features including sharp corners, inclined plane, holes, cylinders, thin walls and so on, indicating the design constraints of SLM, such as the minimum manufacturing resolution, the reliable building angles and the optimization of the surface quality [ 10 ].…”

“…Many researchers [ 10 , 11 , 12 , 13 ] have discussed the manufacturability of metallic parts using SLM under their special investigation condition. Di Wang exhibited the results for manufacturing limits of parts from 316L stainless steel with different geometrical features including sharp corners, inclined plane, holes, cylinders, thin walls and so on, indicating the design constraints of SLM, such as the minimum manufacturing resolution, the reliable building angles and the optimization of the surface quality [ 10 ]. Maciej Mazur [ 11 ] has given out the manufacturing limits Ti-6Al-4V cantilever strut elements through the manufacturing of porous lattice structures, strut diameter of 0.3 mm and inclination angle of 30°.…”