Rapid Manufacturing of Shaped Die and Draw Punch Tools for Presses

Abstract

Traditionally forming tools for a press are machined with a CNC-machine. This is quite time consuming - calculating tool tracks, selecting cutting tools, cutting blanks, design fixation and finally machining - especially for a small batch of parts. One alternative method is to cut a die and a draw punch tools from a blank sheet and bunching the plates. Clamping plates together is fast and easy to implement by using for example studs and bars with a certain tolerance to ensure alignment. A laser, a water jet or a plasma cutter can be used for cutting plates. Especially the laser and the water jet cutting are precise methods giving a fine surface quality without a need for fine-tuning. The method saves material compared with machining because a die and a punch could be cut at the same time from a blank sheet as compatible pair as well as the needed amount of plates could be estimated depending of the length of a pressed product. University of Oulu, Oulu Southern institute, Future Manufacturing Technology -group has manufactured several forming tools within this technique and found it extremely suitable for experimenting different solutions and options fast. Furthermore, the method is likely to help especially SMEs in their R&D-phase by lowering production costs in a cost-efficiency way.

Mechanical Properties of a “Simple Panel Structure” Manufactured of an Ultra High Strength Stainless Steel

“…The downside of folding a corrugated core from ultra-high strength steels (UHSS) for desired geometries is challenging due to a large spring back effect [8,9]. The spring back as high as 35º has been observed for instance with an UHSS steel with the yield strength (YS) of 1600 MPa.…”

“…The spring back as high as 35º has been observed for instance with an UHSS steel with the yield strength (YS) of 1600 MPa. In that case, a 145 mm deep die (a 55º V-slope) with a 30 mm bending radius was required to shape a 100 mm high corrugated core with the 90º corrugation angle between the walls [8]. Also, laser keyhole welding does not allow any air gap between the sheet at the welding line, so that the high uniformity of corrugated sheets is required [10].…”

Designing and Manufacturing of a Flexible Longitudinally Laminated Sandwich Panel Forming Tool

“…In the earlier studies, various models of forming tools for sandwich panels have been investigated [13,14]. Tools have worked well in previous studies meanwhile the versatility of tools have become problematic.…”