Abstract
The present paper is focused on the issue of creating residual stresses in the manufacturing of the moulded parts for injection moulding machines using DMLS technology. Thus, fractures and cracks can cause deformations and geometric inaccuracies in the final part. Moreover, they pose a potential damage risk to the machine itself. The simulation tools for the analysis of the Direct Metal Laser Sintering (DMLS) process were used to expose the critical points of the original monolithic shaped insert in which the highest stresses during the manufacture occur. Subsequently, an alternative solution was created via the optimization of the internal topology. This solution was analysed, and in terms of strength characteristics, compared to the original model in order to ensure the proper function and durability of the manufactured part. The present study was created in cooperation with a company engaged in the production of injection moulds. The internal topology optimization of the part itself is used in combination with the appropriate orientation of the model in the workspace, unlike other research in the given field, where either the model orientation optimization or the support structure is used in this design. However, except for the mentioned reduction of residual stresses, it has a positive effect on mechanical properties, reducing material consumption and savings in time; thus, the obtained results can be applied to other methods of additive manufacturing.
Highlights
Additive manufacturing, often referred to as 3D printing, is defined according to ISO TC 261 norm as a process in which material is joined in thin layers based on data from 3D models created via Computer Aided Design (CAD) system to manufacture the final parts [1]
When variants of components with and without optimization were compared, the results showed a reduction in residual stresses as well as a reduction in material consumption and production time [6,7]
The issue of the creation and reduction of residual stresses in the parts manufactured via the Direct Metal Laser Sintering (DMLS) technology is still relevant, it is the topic of this paper with the places in which the stress is created and its maxima being the main focus of the study
Summary
Often referred to as 3D printing, is defined according to ISO TC 261 norm as a process in which material is joined in thin layers based on data from 3D models created via Computer Aided Design (CAD) system to manufacture the final parts [1]. The study by Panda and Sahoo provides insights into the creation of the complex thermo-mechanical model in order to study the cyclically repetitive thermal load and resulting residual stresses in the DMLS process. They used the finite element method for the calculation model of the analytical solution. The issue of the creation and reduction of residual stresses in the parts manufactured via the DMLS technology is still relevant, it is the topic of this paper with the places in which the stress is created and its maxima being the main focus of the study. The reduction of the manufacturing time and material saving subsequently reducing the cost of production itself can be considered as benefits associated with the alternative solutions [13]
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