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The design of a semi-additive manufacturing shape using metal 3D printing for a partially strengthened mold based on a high-alloy tool steel powder

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Abstract

In this paper, describe the fabrication of high strength punch molds that can be applied to ultra-high strength sheet materials after processing. A method for improving the strength of the punching die by additive manufacturing (AM) of a high strength powder material using a metal 3D printer was proposed. Furthermore, a semi-additive technique was proposed to increase the punch strength through partial AM of specific parts of the punch that require high strength. A preprocessing process for predicting the semi-additive shape for the punch function portion is proposed for application of the AM technology of a metal 3D printer to this semi-additive technique. The preprocessing for determining the semi-additive shape consists of the predicting step of the punch strength based on the shear process of the sheet material, analyzing step the stress distribution of the punch, defining step the semi-additive range, designing step the semi-additive shape, and verifying step the additive interface strength. Based on this simulation, the range of shapes for the semi-additive was 1.21 mm and 2.62 mm for sheet material CP1180 and 1.3 mm and 3.2 mm for sheet material 22MnB5. The shape and range determined in the simulation process defines a semi-additive area (volume) for the 3D printing AM technique using a high-strength powder material, and a semi-additive punch was manufactured according to the defined area. The semi-additive punch (HWS powder material) fabricated in this study was performed a durability test for validity verification in the piercing process of high-strength sheet material (CR980). This validation test compared the state of the punch after 1000 piercing processes with a typical cold piercing punch (SKD11 solid material). From this test, the feasibility of the semi-additive punch was confirmed by showing a similar state of scratches and abrasion from the two punches. The simulation analysis processor for the additive shape and the additive range prediction for the semi-additive punch manufacturing presented in this paper can be useful for the additive manufacture of cutting and trimming punch mold.

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Acknowledgments

This research was supported by The Leading Human Resource Training Program of Regional Neo Industry through the National Research Foundation of Korea funded by the Ministry of Science, ICT and future Planning (2016H1D5A1910621).

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Correspondence to Soon-Yong Yang.

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Gaoqi Zhang is a master student of the University of Ulsan, Ulsan, Korea. He received his B.S. degree in Automotive Engineering from Kookmin University. His research interests include metal 3D printing technology, and simulation, dynamics, CAD, CAE.

Shiliang Wang is a researcher at Institute of Turbine and Propulsion Systems of Zhejiang University, Hangzhou, China. He received his M.S. in Mechanical Engineering from University of Ulsan. His research interests include metal 3D printing technology, and simulation, dynamics, CAD, CAE.

Yong-Seok Kim is a Research Professor of the School of Mechanical Engineering, University of Ulsan, Ulsan, Korea. He received his Ph.D. in Mechanical Engineering from University of Ulsan. His research interests include Metal 3D printing technology, mechanism design and simulation, dynamics, CAD, CAE.

Seong-Woong Choi is a Ph.D. of the Department of Construction Machinery Engineering, University of Ulsan, Ulsan, Korea. He received his M.S. in Mechanical Engineering from University of Ulsan. His research interests include future construction machinery, dual arm field robot, metal 3D printing technology.

Young-Jin Yum is a Professor of the School of Mechanical Engineering, University of Ulsan, Ulsan, Korea. He received his Ph.D. in Aeronautical Engineering from the Korea Advanced Institute of Science and Technology. His research interests include composite material, Metal 3D printing material.

Soon-Yong Yang is a Professor of the School of Mechanical Engineering, University of Ulsan, Ulsan, Korea. He received his Ph.D. in Mechatronics Engineering from University of Tokyo. His research interests include vehicle mechatronics, field robot, silver robot, metal 3D printing technology.

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Zhang, G., Wang, S., Kim, YS. et al. The design of a semi-additive manufacturing shape using metal 3D printing for a partially strengthened mold based on a high-alloy tool steel powder. J Mech Sci Technol 34, 4149–4159 (2020). https://doi.org/10.1007/s12206-020-0907-8

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  • DOI: https://doi.org/10.1007/s12206-020-0907-8

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