Development of Next-generation Tools by ADDitive manufacturING - Step 2

Purpose and goal

The purpose of the project was to develop virtual methods to create tools with better controlled cooling and to pursue material development for additive manufactured tools. Goal completion for this project is considered good. The produced boundary conditions for tempering channels together with recommendations for channel design and an effective manufacturing chain, will result in fast development and production of high pressure die casting tools. The project showed with the demonstrator the possibility of influencing the properties of the component.

Expected results and effects

The results has proven the possibility of printing relatively large tool inserts for high pressure die casting with adapted tempering channels. Large effect on the thermal aspects during production has shown which means that the casting process as well as the quality of the component can be optimised to a larger extent. The results show the importance of process controll at printing to avoid defects in the 3D printed material. The expected effect in the long run is an expanded offer and increased competitiveness for Swedish suppliers within high pressure die casting industry.

Planned approach and implementation

A special test geometry with different design of tempering channels was developed to investigate the effect of different channels. The tests were also used to produce boundary conditions for the simulations that were conducted within the project. A test for geometrical restrictions concernng cleaning of the channels was also produced. Based on an extensive literature review, conditions for the tool material were chosen. All these things together were used to develop, produce and test two tool inserts for production, with adjusted tempering channels in annealed Vibenite® 280.