Design and Validation of 3D-Printed Tools for Stamping of DP600

Asnafi, Nader; Rajalampi, Jukka; Aspenberg, David

doi:10.1088/1757-899x/651/1/012010

Cited by 8 publications

(5 citation statements)

References 0 publications

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“…Fig. 12 shows the shape and the resultant displacements before unloading in the industrial punch with the original solid design and the same punch topology optimized with Both tool versions managed 100,000 strokes [17] the volume/mass fraction of 0.45. This figure displays the results obtained with LS-TaSC in LS-DYNA.…”

Section: Stamping Tools and Diesmentioning

confidence: 99%

“…5): Conventionally designed and 3D-printed with a honeycomb inner structure (left) and 3D-printed after topology optimization using LS-TaSC (right). Material = DIN 1.2709 in both cases [17] Fig. 14: The shape and the resultant displacements prior to unloading in the punch topology optimized using NX12 and targeting a weight reduction by 70% (compared to the conventionally designed solid version) fashions-topology optimization and a honeycomb inner structure.…”

Section: Stamping Tools and Diesmentioning

confidence: 99%

See 1 more Smart Citation

Production Tools Made by Additive Manufacturing Through Laser-based Powder Bed Fusion

Asnafi

Rajalampi²,

Aspenberg³

et al. 2020

Berg Huettenmaenn Monatsh

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This paper deals with the design and production of stamping tools and dies for sheet metal components and injection molds for plastic components. Laser-based Powder Bed Fusion (LPBF) is the additive manufacturing method used in this investigation. Solid and topology optimized stamping tools and dies 3D-printed in DIN 1.2709 (maraging steel) by LPBF are approved/certified for stamping of up to 2-mm thick hot-dip galvanized DP600 (dualphase steel sheet). The punch in a working station in a progressive die used for stamping of 1-mm thick hot-dip galvanized DP600 is 3D-printed in DIN 1.2709, both with a honeycomb inner structure and after topology optimization, with successful results. 3D printing results in a significant lead time reduction and improved tool material efficiency. The cost of 3D-printed stamping tools and dies is higher than the cost of those made conventionally. The core (inserts) of an injection mold is 3D-printed in DIN 1.2709, conformal cooling optimized and 3D-printed in Uddeholm AM Corrax, and compared with the same core made conventionally. The cooling and cycle time can be improved, if the injection molding core (inserts) is optimized and 3D-printed in Uddeholm AM Corrax. This paper accounts for the results obtained in the above-mentioned investigations.

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Section: Stamping Tools and Diesmentioning

confidence: 99%

Section: Stamping Tools and Diesmentioning

confidence: 99%

Production Tools Made by Additive Manufacturing Through Laser-based Powder Bed Fusion

Asnafi

Rajalampi²,

Aspenberg³

et al. 2020

Berg Huettenmaenn Monatsh

Self Cite

View full text Add to dashboard Cite

show abstract

“…In recent years, the manufacture of additively manufactured tools has bloomed. For example, the powder bed fusion technology has allowed the manufacturing of steel stamping tools [208]. Other materials that can be processed with powder bed fusion technologies are CoCr alloys, Ni alloys, Ti alloys, Al alloys, and ceramics [209].…”

Section: Use Of 3d Printed Toolsmentioning

confidence: 99%

Influence of Honing Parameters on the Quality of the Machined Parts and Innovations in Honing Processes

Sender

Buj-Corral

2023

Metals

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The article presents a literature review dealing with the effect of the honing parameters on the quality of the machined parts, as well as with the recent innovations in honing processes. First, an overview about the honing and the plateau-honing processes is presented, considering the main parameters that can be varied during machining. Then, the influence of the honing parameters on surface finish, shape deviation and material removal rate is presented. Finally, some special and innovative applications of the honing process are described. For example, honing with variable kinematics allows obtaining oil grooves that are not rectilinear but curvilinear, in order to reduce the temperature of the part during machining and thus obtaining better surface finish and lower shape deviation. Automation of the honing machines is useful to improve both the production and the verification process. Another innovation consists of using 3D printed tools in honing processes, which will help to obtain abrasive tools with complex shapes, for example by means of powder bed fusion processes.

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“…On the other hand, several studies analyse the influence of using metal AM to solve problems regarding heat dissipation, for instance, by using conformal cooling and mainly related to injection moulds [5][6] or hot stamping [7].…”

Section: Introductionmentioning

confidence: 99%

Improvement of the Thermal Performance of a Drilling Tool Case by Using Metal Additive Manufacturing

Galleguillos,

Hervás,

Periñán

et al. 2023

KEM

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Metal Additive Manufacturing (AM) has been established as one of the most promising solutions when producing new components due to its advantages in creating complex geometries and adding new functionality to the parts. An example of the last, is the usage of conformal cooling in the tooling industry to improve the thermal behaviour of components in-service. The application of this solution is even more meaningful when using metallic materials with high thermal conductivities (e.g. Aluminium alloys). These are mainly selected when the final weight is a key factor in the final component performance, compared with other conductive materials like copper alloys. This study presents the improvement of the thermal behaviour of a drilling tool case manufactured in Aluminium. The selected application case lacks the possibility of evacuating the heat produced by an engine. A redesign of the component is presented, considering the advantages of Powder Bed Fusion – Laser/Metal (PBF-L/M). Both passive and active heat dissipation are analysed by including the reticular structure and internal cavities with forced air. The study is performed first at coupon level and later in the redesigned case manufactured by PBF-L/M. Infrared Thermography (IRT) inspections are conducted to investigate the thermal dissipation when heating the components, and also to monitor the cooling down process. A comparative thermal analysis between the initial case manufactured by the conventional process and the redesigned AM case is also presented.

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Design and Validation of 3D-Printed Tools for Stamping of DP600

Cited by 8 publications

References 0 publications

Production Tools Made by Additive Manufacturing Through Laser-based Powder Bed Fusion

Production Tools Made by Additive Manufacturing Through Laser-based Powder Bed Fusion

Influence of Honing Parameters on the Quality of the Machined Parts and Innovations in Honing Processes

Improvement of the Thermal Performance of a Drilling Tool Case by Using Metal Additive Manufacturing

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