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

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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.