Functionalization of additively manufactured press hardening dies by roller burnishing

通过滚光抛光增材制造模压硬化模具的功能化

• 批准号: 417202720
• 负责人: Professor Dr.-Ing. A. Erman Tekkaya
• 金额: --
• 依托单位: Institut für Umformtechnik und Leichtbau (IUL)
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2019
• 资助国家: 德国
• 起止时间: 2018-12-31 至 2022-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/417202720?language=en
• 关键词: Functionalization; additively; manufactured; press; hardening

A novel tooling technology for press hardening is to be developed in which the tools are manufactured additively by means of laser powder deposition. The thermal requirements are locally adjusted and finished by a forming operation of the tool surface. The idea is to use the heat resulting from the building process in order to systematically level the die surface for the purpose of influencing the material flow during warm sheet metal forming as well as to adjust the heat transfer between the die and the workpiece. The implementation is to be carried out in the combination machine available at the IUL for additive manufacturing by means of laser powder deposition and milling. In the research project the machine is to be equipped with tools for roller burnishing (e.g. hydrostatically supported rolling tools). The execution of the laser powder deposition and the finishing by forming operations in one machine and one clamping allows smoothing regions/surfaces which are otherwise not or only hard to reach during the additive manufacturing of the dies. An analytical model is to be used to describe the surface topography after rolling of additively manufactured components. The model is used for the process result of significant factors, e.g. the rolling path distance, different ball diameters, and different original surfaces resulting from the building process.In contrast to processes working in the powder bed, in laser powder deposition there is no possibility of supporting overhangs by unmelted powder. In this project manufacturing strategies for the manufacturing of cooling channels shall be elaborated. By varying the overhangs of the weld beads and the angle of incidence of the welding unit, the geometrical complexity of the cooling channels will be enhanced increasingly right up to three-dimensionally running channels. With a demonstrator tool the effectiveness of micro-structured tool surfaces and the integration of three-dimensionally running cooling channels on the local heat balance and the local component properties during press hardening shall be investigated and demonstrated, respectively.In the long term, it is the aim to use the heat remaining in the workpiece from the laser melting process for the rolling process in order to increase e.g. the forming capacity and to reduce the flow stress.

将开发一种新型的压制硬化模具技术，其中通过激光粉末沉积的方式增材制造模具。热要求通过工具表面的成形操作进行局部调整和精整。其理念是利用成型过程中产生的热量，系统地平整模具表面，以影响金属板温成形过程中的材料流动，并调节模具和工件之间的热传递。该实施将在IUL提供的组合机器中进行，用于通过激光粉末沉积和铣削进行增材制造。在研究项目中，机器将配备用于滚柱抛光的工具（例如，静压支撑的滚柱工具）。在一台机器和一次夹持中执行激光粉末沉积和通过成形操作进行精加工允许平滑区域/表面，否则这些区域/表面在模具的增材制造期间无法到达或仅难以到达。将使用分析模型来描述增材制造组件轧制后的表面形貌。该模型可用于处理重要因素的结果，例如滚道距离、不同的球径以及成型过程中产生的不同原始表面。与在粉末床中工作的工艺相比，在激光粉末沉积中，不可能由未熔化的粉末支撑悬突。在本项目中，应详细说明冷却通道的制造策略。通过改变焊道的悬伸和焊接单元的入射角，冷却通道的几何复杂性将逐渐提高到三维延伸通道。使用演示工具，应分别研究和演示微结构化工具表面的有效性以及三维运行冷却通道对局部热平衡的集成和压制硬化过程中的局部部件性能。从长远来看，目的是将来自激光熔化过程的工件中剩余的热量用于轧制过程，提高生产能力，降低流动应力。