Design, analysis and principle demonstration of incrementally manufactured, modular lightweight die casting tools

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Most of the components for conventional die casting tools are still designed to order and are manufactured using subtractive processes. However, the current production principle has its inherent disadvantages. For example, high tool weights and a high resource input during production lead to thermally inert tools. Due to the high tool mass, a considerable amount of energy is still required for tool temperature control. Taking into account the usual tool weights of die casting tools and the characteristic application rates of different metallic generative processes, it also becomes obvious that there are currently narrow limits to the widespread application of additive manufacturing processes. Prospective approaches to the increased use of a modular or standardized design to reduce manufacturing costs while retaining conventional, subtractive manufacturing processes have already been demonstrated. However, casting tools could be made available with considerably reduced material input and manufacturing costs as well as improved energetic properties if the tool design would be based on lightweight design principles. As a result, only the individual tool cavity itself is produced by cutting processes. The other tool components can be modular and reusable, e.g. by means of supporting structures with members and nodes, which can be adapted to the geometric requirements by incremental manufacturing methods. The overall objective of the project proposed here is therefore to achieve a methodology for lightweight design and the incremental manufacturing of modular lightweight die-casting tools. In addition to production-related advantages, this type of lightweight tool could overcome numerous technological restrictions of conventional die casting tools. Hence, lower energy requirements in foundries, improved tool temperature control and a more targeted influence on component properties, shorter set-up times, better manageability and lower mechanical system stress or higher system dynamics can be achieved. The lightweight design of die casting tools in conjunction with a high degree of modularity also promotes the increased use of additive manufacturing processes. Contrary to existing additive manufacturing processes, it also aims to produce components step by step according to additive basic principles based on mass-produced semi-finished products. This also enables increased flexibility in production, shorter production times and lower material and energy requirements for the fabrication of die casting tools. However, the implementation of this approach raises a number of scientific questions with regard to the achievable tool and component properties. At present, only very limited knowledge exists with regard to the design, dimensioning, manufacturing and use of lightweight die casting tools. The application of incremental production methods is seen as an approach to overcoming these production restrictions.