Applying Additive manufacturing to Aluminum tool part design

附加制造(AM)指的是一种新兴的技术，它通过在最终形状或接近最终形状的情况下逐层控制地添加材料，具有或不具有复杂的内部结构，使用最少的加工量来构建3D对象。在操作过程中施加的多次热旋转中，模具和模具的性能可以通过允许保持均匀温度场的技术来提高。AM正在成为一种能够通过在战略位置插入保形冷却通道来提供这种优势的制造技术。这一综合热管理概念将减少占空比(提高生产率)，增加处理能力，并提高盈利能力。然而，此类模具的设计和制造中的大多数基本概念仍有待定义。在此背景下，NSERC-CQRDA联合提案旨在定义：(1)针对具有热管理系统的模具的添加制造(DFAM)设计的优化方法，(2)如何使用新型高强度/高导热系数粉末制造具有复杂冷却通道系统的此类刀具和模具，以及(3)如何获得具有兼容特性的表面，以满足铝成形行业的要求。这些基本的知识差距将在这个项目中得到解决。这种高性能工具的可用性是这个项目的工业赞助商，即Verbom、Exco Engineering、Trumpf和Altec的关键利益所在。所有这些公司都将从提高竞争力和产品组合中受益，从而实现业务增长的最终目标，这将有助于提高加拿大在工具和运输部门采用AM技术方面的地位。

Additive Manufacturing (AM) refers to an emerging class of technologies that build 3D objects by the controlled addition of materials in a layer-by-layer fashion, at or near their final shape, with or without complex internal structures, using a minimum amount of machining.Dies and molds, from the numerous thermal gyrations imposed during operation, could have their performance improved by the availability of technologies permitting to maintain a uniform temperature field. AM is becoming an enabling manufacturing technology capable of providing such advantages by the insertion of conformal cooling channels in strategic locations. This integrated thermal management concept will allow a reduction in the duty cycle (increased production rate), an increase in the processing capacity and an improvement of the profitability. However, most of the fundamental concepts in the design and manufacturing of such dies and molds remain to be defined. In that context, this joint NSERC-CQRDA proposal is established to define: (1) optimized methods for design for additive manufacturing (DFAM) of tooling with thermal management systems, (2) how to fabricate such tools and dies with complex cooling channel systems using new high strength/high thermal conductivity powders and (3) how to obtain surfaces with compatible characteristics for the Al forming industry. These fundamental knowledge gaps will be answered during this project.The availability of such high-performance toolings is of key interest to the industrial sponsors of this project, namely Verbom, Exco Engineering, Trumpf and AlTec. All of them will benefit by improving their competitiveness and product portfolio, leading to the ultimate goal of business growth, which will contribute to improving Canada's position in the adoption rate of AM technologies in the tooling and transportation sector.