Development of an AM testing tool using SLM to investigate process-related stresses in thev first draw of the thermal multi-stage deep-drawing process

Introduction/Purpose:
In multi-stage deep drawing, the local temperature development during forming and mechanical loads on the active parts of tools and sheets are important factors for their service life and the quality of the components to be produced.These components undergo a high degree of deformation, leading to a change in component properties during the individual forming stages. The conditions of these individual stages all depend on the preceding ones and in particular from the first draw. In addition, chemical differences in the materials used lead to quality margins, which can change the product properties significantly.

Methods:
In order to ensure stable & optimized component properties when using sheet metal with limited formability, it is possible to manufacture tools that can overcome this restriction and at the same time are able to reduce the stresses applied to the tools and the components to be manufactured. Results Within the scope of this work, a well instrumented additive manufactured test tool using selective laser melting for controlled temperature application is developed and active tool parts are validated under industry-related conditions.

Conclusions:
Possibilities are shown to realize segmented heating and cooling zones in order to reduce the tribological and mechanical loads on tools and components to be manufactured. The results show that a more stable process control can be achieved by an intentional heat input into certain areas of the tools while simultaneously cooling others. Above all, FEM simulations are carried out in order to compare the numerically determined results with the experimental deep-drawing process and to adapt them accordingly.