Abstract
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 (dual-phase 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.
Highlights
The state-of-the-art for additive manufacturing of metals is described in [1]
Stamping tools and dies and injection molding core/inserts are the tool types that this study focuses on
Three measures were used to evaluate the tools in Fig. 8: the mass fractions of the design region, the maximum von Mises stress in the design region during the complete simulation, and the vertical displacement time history of a node slightly above the draw radius
Summary
The state-of-the-art for additive manufacturing of metals is described in [1]. Additive manufacturing is subject to a technology assessment in [2]. Based on these and other relevant reviews, the research needs and challenges for the Swedish industrial use of metal additive manufacturing were identified [3]. The development of new metal powders and the use of the new design options were among the identified needs and challenges in [3]. This investigation deals with tool design and production using Additive Manufacturing through Laser-based Powder Bed Fusion (LPBF), even called AM or 3D-printing. Stamping tools and dies and injection molding core/inserts are the tool types that this study focuses on
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