Naslov
Experimental AM drawing tool

Autori
Horvatek Marko

Vrsta, podvrsta i kategorija rada
Sažeci sa skupova, prošireni sažetak, stručni

Izvornik
SIAMM22 Book of Abstracts / - , 2021, 78-79

Skup
2nd International Workshop on Structural Integrity of Additively Manufactured Materials – SIAMM22

Mjesto i datum
Brno, Češka Republika, 04.02.2022. - 05.02.2022

Vrsta sudjelovanja
Predavanje

Vrsta recenzije
Međunarodna recenzija

Ključne riječi
Additive manufacturing ; drawing tools, experimental tooling

Sažetak
Global economy shift from mass production of products to personalized production challenges traditional manufacturing processes. Requirement for shorter prototype development times led to development of highly customizable forming processes such as incremental sheet forming [1]. Available tooling processes require either a large infrastructure or high tooling costs in order to achieve manufacturing flexibility [2, 3]. One of the technologies that allows production of vide variety of products is rubber pad forming (RPF). By replacing one of the tool sides with rubber pad it allows faster and more affordable tooling production, but still requires die traditionally produced out of metal. Solid metal die can be produced on milling machine, which leads to high tooling cost and lead-time. To shorten the lead-time and make toolmaking more affordable additive manufacturing (AM) processes may be used. Fused deposition modelling (FDM) as manufacturing process is well suited for tool making for cold deformation of sheet metal. Additive manufacturing allows creation of both tool sides, eliminating the need for elastomer used in RPF and allowing the creation of more complex tooling. FDM manufacturing process is also well suited as it provides wide variety of the production materials and new material blends are still under research [4]. In the forming tools application, key properties of used material are: 1) Stiffness – determines final part accuracy, 2) Strength – limits the loading force on the forming tool, 3) Brittleness - increases the risk of tool snapping [5]. Experimental part of the research was performed on forming tools produced out of 3 different polymer materials: ABS, PLA and PEI. All materials were printed using FDM technology, on printer with enclosed build chamber with the infill of 90%. Tools were used for forming of 1, 5 mm aluminium sheet (Al 99, 5) using 30 ton hydraulic press. In order to determine the force needed for deformation preliminary pulls were used. The force of 250 kN was sufficient for complete geometrical definition of the part. 10 deformation cycles were performed with each tool made at 250 kN force setting. Tool wear was monitored optically and after completion of all deformation cycles, tools were measured with optical scanner GOM Atos 300. ABS material preformed the worst with visible layer tear after 10 deformation cycles (picture 1). Rest of the tools (PLA and PEI) showed no significant visual defect other than rounding of the sharp edges. After 10 deformation cycles measurement with optical scanner was performed in order to detect maximal deformations per material. Deviations from initial form in range from 0, 1 mm on PEI to 0, 42 mm on ABS part were measured. From tested materials ABS performed the worse of all. Better results in terms of tool wear resistance can be achieved by using PLA or PEI materials. When comparing those two materials PLA stands out as much easier to manufacture and overall, more affordable material. Although PLA is well suited for most applications on higher temperature and more demanding geometries PEI could provide better wear resistance. The experiment confirms the feasibility of using form tools manufactured by using AM. In modern production, where “time is money” the demand for fast tooling prototyping could be solved with FDM manufacturing. In addition, the demand for great level of flexibility and customer-specific variants could be met with usage of AM tools as they minimize lead-time and provide cost efficient solution for small series tool production.

Izvorni jezik
Engleski

Znanstvena područja
Strojarstvo

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