Resources and manufacturing technology evaluation of hybrid additive metal laminated tooling for forming

Resources and manufacturing technology evaluation of hybrid additive metal laminated tooling for forming


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Abstract. The rough surface finish caused by the stair step effect is the major drawback in the application of sheet metal laminates in rapid tooling. The application of laser metal deposition (LMD) and subsequent post-processing (milling, ball burnishing, and laser polishing) to reduce the stair-step effect in hybrid additive metal laminated forming tools was recently presented. In the present study, the energy consumption and manufacturing time of the hybrid process are compared with the conventional (milling plus hardening by heat treatment) as well as with full LMD and milled components. The hybrid process requires significantly less energy and manufacturing time compared to the LMD components. Since the surface hardness is sufficient for tooling in the hybrid process, no additional hardening is required, also resulting in a shorter manufacturing time and lower energy relative to the conventional method (depending on the part mass, a minimum of 29% is faster). The optimal sheet laminate combination based on the economic criteria for the tool with a radius of 6 mm is presented.

Sheet Metal Lamination, Laser Metal Deposition, Deep Drawing Tools

Published online 4/19/2023, 10 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: DARDAEI JOGHAN Hamed, HAHN Marlon, AGBOOLA Ololade, TEKKAYA A. Erman, Resources and manufacturing technology evaluation of hybrid additive metal laminated tooling for forming, Materials Research Proceedings, Vol. 28, pp 21-30, 2023


The article was published as article 3 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

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