Process model for the tool-free production of metallic components with the Arburg Freeforming Process

采用Arburg Freeforming工艺的无工具生产金属部件的项目工艺模型将通过使用金属原料沿着Arburg Freeforming工艺，将传统的基于工具的金属注射成型（MiM）工艺扩展为灵活的MIM工艺。这为金属部件的创成生产提供了一种新的灵活方法。由于与传统注塑成型工艺高度相似，它在部件质量（形状持久性和机械性能）方面具有很高的能力。此外，由于没有成型模具，它具有很高的经济潜力。基于Arburg自由化过程的新奇，该过程尚待审查，并且没有关于过程设计或模型的建议。为了利用现有的潜力，材料，工艺和喷嘴几何参数的影响和相互作用必须通过实验设计（DoE）进行统计评估。该方法的目标是评估用于从材料17-4PH生产金属部件的柔性MIM工艺，由于其在工业中的广泛使用，该材料被认为是具有代表性的。通过这种实验，应该开发出一个过程模型。此外，还将评估两个连续系列的实验，每个实验具有不同的样品几何形状。在第一系列实验中，材料、工艺和喷嘴几何参数对尺寸稳定性（尺寸稳定性、平整度、粗糙度）和机械性能（拉伸强度、硬度、密度）结果的影响和相互作用将根据拉伸样本和立方体来确定。这些几何形状具有简单的几何形状规格（没有复杂的过渡），因此可以检测机械特性（例如抗拉强度、密度），以创建基本的工艺模型。在基于复杂几何形状的第二次测试中，具有复杂几何形状规格（齿面曲线）的齿轮，将验证现有过程模型（研究先前变量）并增强（研究新变量：尺寸齿面曲线）。将根据第一个试验系列的结果选择要改变的参数的因子水平。结果不仅应包括用于柔性MIM工艺的描述性工艺模型方程，还应包括用于未来应用和材料的材料、工艺和喷嘴几何参数选择的建议。预期的结果将成为工艺理解和工艺优化的基础，最终将反映在高质量的组件上。

The Project Process model for the tool-free production of metallic components with the Arburg Freeforming Process will expand the conventional tool based Metal Injection Molding (MiM) process, through the use of a metal Feedstock along with the Arburg Freeforming Process, to a flexible MIM Process. This presents a new, flexible approach for the generative production of metallic components. Due to high similarities to the conventional injection molding process it has a high capability in terms of component quality (shape-persistence and mechanical properties). Additionally it has high economic potential due to the absence of shaping molds. On the basis of the novelty of the Arburg Freefoming Process, the process has yet to be examined and there are no recommendations as to a process design or model. In order to harness the available potential, the influences and interactions of materials, process and nozzle geometry parameters have to be statistically evaluated through a design of experiments (DoE). The approach target is to evaluate the flexible MIM process for the production of metallic components from the material 17-4PH, which is regarded as representative due to its widespread use in industry. By means of this experimentation a process model should be developed. Alongside will be evaluated two sequential series of experiments each with different sample geometries. In the first series of experiments the influence and interaction of materials, process and nozzle geometry parameters on the outcomes of dimensional stability (dimensional stability, flatness, roughness) and mechanical properties (tensile strength, hardness, density) will be determined based on tensile specimens and cubes. These geometries have simple geometry specifications (no complex transitions) and therefore allow the detection of mechanical characteristics (e.g. tensile strength, density) for creating a basic process model. In the second test based on a complex geometry, a gear which has complex geometry specifications (tooth flank curves), the existing process model will be validated (investigation of previous variables) and enhanced (investigation of new variables: dimensional tooth flank curves). The choice of factor levels for the parameters to be varied will be derived from the results of the first test series. A result should not only include descriptive process model equations for the flexible MIM process but also recommendations for materials, process and nozzle geometry parameter choices for future applications and materials. The expected results will form the basis for process understanding and process optimization, which will ultimately be reflected in a high component quality.