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深拉深模具柔性制造工艺链。相应的大批量模体是由单片层快速而经济地制造出来的。发生的台阶，可能会因层压分层而变化，将由激光粉末沉积填充，最后，通过滚轮抛光使活动模具区域平滑。除了节省能源，这种工艺组合也比传统的深拉深模具制造更快，更便宜，应该根据这些标准进行审查。实施将在IUL可用的组合机器中进行，通过激光粉末沉积和铣削进行增材制造。机器将配备滚轮抛光工具。为了减少叠层制造模具的台阶效应，需要开发的第一步技术是用激光粉末沉积填充台阶。在第二步中，与滚筒抛光相结合，检查不同的方法来减少台阶效应，并比较不同的工艺路线。为了设计基于这种新型组合的刀具，需要建立一个估算刀具等效应力的解析模型。平条拉伸试验考察生产表面的摩擦学性能。开发的基本原理被转移到不同复杂性的拉伸工具上，并在成形测试中检查可实现的部件质量和磨损发展。最后，对待开发的技术进行了技术、经济和能源评价。

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.