Reducing the stair step effect for dies manufactured by layer-laminated manufacturing by additive and formative post-processing

通过增材和成形后处理减少层压制造模具的阶梯效应

• 批准号: 426515407
• 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 2021-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/426515407?language=en
• 关键词: Reducing; stair; step; effect; dies

A resource-efficient process chain for the flexible manufacturing of dies for deep drawing processes is to be developed. The corresponding high-volume base body of the die is manufactured fast and cost-efficiently from single sheet layers. The occurring stair steps, which may vary due to the lamination layering, are to be filled by laser powder deposition and, finally, the active die areas are smoothed through roller burnishing. Besides saving energy, this process combination is also faster and cheaper than conventional die manufacturing for deep drawing and shall be reviewed in terms of these criteria. 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. The machine will be equipped with tools for roller burnishing. The first step of the technology to be developed for the reduction of the stair step effect for dies manufactured by layer-laminated manufacturing is filling the steps by laser powder deposition. In a second step, the combination with roller burnishing takes place, examining different approaches for the reduction of the step effect and also comparing alternative process routes. For the design of the tools based on the novel combination an analytical model for estimating the equivalent stress acting in the tool is to be developed. The flat stripe tensile test investigates the produced surfaces regarding their tribological properties. The fundamentals developed are transferred to drawing tools of different complexities and examined in forming tests with regard to the achievable component quality and wear development. Finally, a technological, economic, and energetic evaluation of the technology to be developed is carried out.

为实现拉深模具的柔性制造，需要开发一种资源节约型的工艺链。从单片层快速且经济高效地制造相应的大容量模具底座。出现的阶梯台阶可能会因层压分层而不同，将通过激光粉末沉积来填充，最后，通过滚轮抛光来平滑活跃的模具区域。除了节约能源，这种工艺组合也比传统的拉深模具制造更快、更便宜，并应根据这些标准进行审查。实施将在IUL提供的组合机中进行，以通过激光粉末沉积和球磨进行添加制造。这台机器将配备滚轮抛光工具。为减少层叠制造模具的阶梯效应而开发的技术的第一步是用激光粉末沉积填充阶梯。在第二步中，与滚轮打磨相结合，检查减少台阶效应的不同方法，并比较不同的工艺路线。对于基于这种新型组合的工具设计，需要建立一个分析模型来估计作用在工具中的等效应力。平条拉伸试验研究所产生的表面的摩擦学特性。开发的基本原理被转移到不同复杂程度的绘图工具上，并在成形试验中进行了关于可实现的部件质量和磨损发展的检查。最后，对拟开发的技术进行了技术、经济和活力评价。