Reducing the Stair Step Effect for Dies Manufactured by Layer-Laminated Manufacturing by Additive and Formative Post-Processing

Funding: German Research Foundation (DFG)
Project: 426515407
Contact: Hamed Dardaei Joghan M. Sc.

The aim of the project is to develop a resource-efficient process chain for the flexible manufacturing of dies for deep drawing processes.

The corresponding high-volume base body of the die is manufactured in a fast and cost-efficient way from varying single sheet metal layers. The occurring ‘stair steps’, which always result from the layering of the sheets, are to be filled subsequently by laser powder deposition (LPD) and, eventually, the active die areas are to be smoothed through roller burnishing employing different strategies. In this context, the weld seam as well as the bonding quality to the sheets has to be characterized thoroughly. An analytical description is supposed to ease the design process for the layer-laminated tool. 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 is carried out.

Process chain of manufacturing a hybrid deep drawing tool