Abstract
Rapid Tooling processes are developing and proving to be a reliable method to compete with subtractive techniques for tool making. This paper investigates large volume production of components produced from Selective Laser Melting (SLM) fabricated injection moulding tool inserts. To date, other researchers have focused primarily on investigating the use of additive manufacturing technology for injection moulding for low-volume component production rather than high volume production. In this study, SLM technology has been used to fabricate four Stainless Steel 316L tool inserts of a similar geometry for an after-market automotive spare part. The SLM tool inserts have been evaluated to analyse the maximum number of successful injections and quality of performance. Microstructure inspection and chemical composition analysis have been investigated. Performance tests were conducted for the four tool inserts before and after injection moulding in the context of hardness testing and dimensional accuracy. For the first reported time, 150,000 injected products were successfully produced from the four SLM tool inserts. Tool inserts performance was monitored under actual operating conditions considering high-level demands. In the scope of this research, SLM proved to be a dependable manufacturing technique for most part geometries and an effective alternative to subtractive manufacturing for high-volume injection moulding tools for the aftermarket automotive sector.
Highlights
Selective Laser Melting (SLM) is an additive manufacturing (AM) process that produces three-dimensional (3D) functional metallic parts [1,2] directly from CAD data by selectively melting metallic powder using a laser beam, forming near net-shaped layered components that typically require post processing for surface finish improvement [3,4]
Studies have discussed an approach to improving AM techniques to provide a better-quality surface finish on fabricated metallic parts [9,10]
The framework methodology employed in this study is structured to outline the major steps this research work follows: firstly, the four Stainless Steel 316 L tool inserts required for investigating this study were fabricated simultaneously using SLM technology
Summary
Selective Laser Melting (SLM) is an additive manufacturing (AM) process that produces three-dimensional (3D) functional metallic parts [1,2] directly from CAD data by selectively melting metallic powder using a laser beam, forming near net-shaped layered components that typically require post processing for surface finish improvement [3,4]. AM processes facilitate fabrication of geometrically complex components and freeform designs, as opposed to the limitations associated with conventional subtractive machining [5,6]. Despite these positive aspects, AM techniques continue to exhibit disadvantages that must be addressed and surpassed [7,8]. Studies have discussed an approach to improving AM techniques to provide a better-quality surface finish on fabricated metallic parts [9,10]. In this context, Ahn and Yakout et al [11,12]. Advances in AM are progressing to improve surface finish, dimensional accuracy, and durability; advances in machining research are in progress [15]
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