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

开发一种资源高效的工艺链，用于深冲工艺模具的柔性制造。模具的相应大体积基体由单层板快速且经济地制造。出现的阶梯可能因层压分层而变化，将通过激光粉末沉积填充，最后，通过辊抛光使有源芯片区域平滑。除了节省能源，这种工艺组合也比传统的深冲模具制造更快，更便宜，应根据这些标准进行审查。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。机器将配备用于滚柱抛光的工具。为减少通过层压制造制造的模具的阶梯效应而开发的技术的第一步是通过激光粉末沉积填充台阶。在第二步中，与辊抛光相结合，检查减少阶梯效应的不同方法，并比较替代工艺路线。对于基于新组合的工具的设计，将开发用于估计作用在工具中的等效应力的分析模型。平条拉伸试验研究了所产生的表面的摩擦学性能。开发的基本原理被转移到不同复杂性的绘图工具，并在成形测试中检查可实现的部件质量和磨损发展。最后，进行了技术，经济和能量的技术开发进行评估。

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.