Development of sheet metal forming dies with excellent mechanical properties using additive manufacturing and rapid tooling technologies

2016 ◽  
Vol 90 (1-4) ◽  
pp. 21-25 ◽  
Author(s):  
Chil-Chyuan Kuo ◽  
Ming-Ren Li
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Rapid Tooling

APPLICATION OF 3D PRINTING TECHNOLOGY FOR RAPID TOOLING IN SHEET METAL FORMING

2020 ◽  
Vol 3 ◽  
pp. 20-30
Author(s):  
M.A. SEREZHKIN ◽  
D.O. KLIMYUK ◽  
A.I. PLOKHIKH
Keyword(s):  
3D Printing ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Rapid Tooling ◽  
Printing Technology ◽  
3D Printing Technology ◽  
3D Printed ◽  
Printed Materials ◽  
Printing Parameters

The article presents the study of the application of 3D printing technology for rapid tooling in sheet metal forming for custom or small–lot manufacturing. The main issue of the usage of 3D printing technology for die tooling was discovered. It is proposed to use the method of mathematical modelling to investigate how the printing parameters affect the compressive strength of FDM 3D–printed parts. Using expert research methods, the printing parameters most strongly affecting the strength of products were identified for further experiments. A method for testing the strength of 3D–printed materials has been developed and tested.

Sheet metal forming behaviour and mechanical properties of TRIP steels

1999 ◽  
Vol 70 (11) ◽  
pp. 472-479 ◽  
Author(s):  
Wolfgang Bleck ◽  
Joachim Ohlert ◽  
Kostas Papamantellos
Keyword(s):  
Mechanical Properties ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Trip Steels ◽  
Forming Behaviour

Bending and Stamping Processes of FSWed Thin Sheets in AA1050 Alloy

2014 ◽  
Vol 622-623 ◽  
pp. 459-466 ◽  
Author(s):  
Michela Simoncini ◽  
Lorenzo Panaccio ◽  
Archimede Forcellese
Keyword(s):  
Mechanical Properties ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Preliminary Investigation ◽  
Thin Sheets ◽  
Microstructural Investigation ◽  
Bending Tests ◽  
Friction Stir ◽  
Hemispherical Punch

The present investigation aims at studying post-welding forming operations of friction stir welded AA1050 aluminium thin sheets. A preliminary investigation has allowed to define the rotational and welding speed values leading to friction stir welded joints with high mechanical properties. Then, formability and elastic springback were evaluated using the hemispherical punch and bending tests, respectively. A microstructural investigation has allowed to relate the mechanical properties of joints to microstructure. Finally, the friction stir welded assemblies were subjected to air bending and stamping experiments in order to evaluate their attitude to undergo to sheet metal forming operations.

scholarly journals Influence of Stress States on Forming Hybrid Parts with Sheet Metal and Additively Manufactured Element

2021 ◽  
Author(s):  
Jan Hafenecker ◽  
Thomas Papke ◽  
Marion Merklein
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Sheet Metal ◽  
Metal Forming ◽  
Forming Process ◽  
Powder Bed ◽  
Geometrical Properties ◽  
Hybrid Parts ◽  
Metal Materials ◽  
Stress States

AbstractHybrid parts with additively manufactured elements (AME) combine the advantages of two or more manufacturing processes, e.g., forming and additive manufacturing (AM), and thus offer a solution to the increasing demands of industrial trends such as personalized mass production. Despite their advantageous properties, research in this field still lacks in clear classification and process interactions. Due to the strong influence of the AME on the formability of hybrid parts, the combination of laser-based powder bed fusion (PBF-LB) with subsequent sheet metal forming is examined in this paper. Therefore, cylindrical functional elements are built up on sheet metal and the resulting hybrid components are subsequently formed. Common forming processes such as bending, stretch forming and deep drawing are compared in regard to the different stress states. The results show a reduction in formability for hybrid components compared to conventional sheet metal materials. Reasons found are geometrical properties, gradients of mechanical properties and induced stresses. Consequently, requirements for the additive manufacturing process regarding a subsequent forming process are outlined. Namely, the gradient of mechanical properties should be smoothened, residual stresses kept low and the design of AMEs should avoid stress concentration.

Rapid Tooling for Sheet Metal Forming Using Profiled Edge Laminations—Design Principles and Demonstration

1998 ◽  
Vol 120 (4) ◽  
pp. 746-754 ◽  
Author(s):  
D. F. Walczyk ◽  
D. E. Hardt
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
General Procedure ◽  
Formal Analysis ◽  
Design Principles ◽  
Rapid Tooling ◽  
Cnc Machining ◽  
Die Geometry ◽  
Die Materials

Sheet metal forming dies constructed of laminations offer advantages over more conventional tooling fabrication methods (e.g. CNC-machining) in terms of tooling accessibility, reduced limitations on die geometry and faster fabrication with harder die materials. Furthermore, the recently introduced Profiled Edge Lamination (PEL) tooling method improves upon other lamination-based tooling methods. Adoption of this promising rapid tooling method by industry is being hindered by the lack of formal analysis, design principles, and manufacturing requirements needed to construct dies in such a manner. Therefore, the propensity for delamination of the die is discussed and preventive measures are suggested. The basic machining instructions, i.e., an array of points and directional vectors for each lamination, are outlined for both compound and planar profiled-edge bevels. Laser, AWJ and flute-edge endmilling are experimentally identified as the most promising methods for machining bevels. Development of a stand-alone PEL fabrication machine is suggested over retrofitting commercially-available 5-axis machines. Finally, the general procedure for creating PEL dies is implemented in the construction of a matched set of sheet metal forming tools. These tools are used to successfully stamp a sheet metal part out of draw-quality steel.

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