Kaleem, Muhammad Ali
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Publication Access status: Metadata only , Additive manufacturing of polymeric pressure die for rotary draw bending process3D printing or additive manufacturing (AM) possesses enormous potential to benefit the manufacturing industry. Presently, rotary draw bending (RDB) is one of the most commonly used cold-forming industrial process for bending metal tubes. Pressure die is a fundamental forming tool in RDB processes, and it is conventionally made by various grades of comparatively expensive alloy steels. This research presents a novel design of a pressure die which can be 3D printed by using inexpensive polymeric filaments. In this research paper, the 3D-printed pressure die is named as “FFF-pressure die.” The material used to fabricate the FFF-pressure die is a thermoplastic polymer known as “ecoPLA.” The mechanical properties of ecoPLA are studied in relation to the process conditions of a RDB process. Firstly, an initial feasibility of using the FFF-pressure die in a RDB process is obtained by conducting a quick static stress analysis with actual process conditions. After initial feasibility, a complete RDB process is developed and simulated with actual process conditions and material properties. The FFF-pressure die is then practically fabricated by FFF 3D printer and experimentally tested on an industrial RDB machine. The results of practical experiments are compared with the simulation results. In order to make a comparison of the FFF-pressure die with the conventional metal pressure die, the simulation and practical process is also conducted with the conventional metal pressure die. A performance and cost comparison is made between the polymeric FFF-pressure die and the conventional metal pressure die. Von Mises stresses, contact forces, failure risk, and elastic deformations are analyzed. The advantages and limitations of using the FFF-pressure die in a RDB process are discussed in the end. This research intends to widen the avenue of using cost-effective and lightweight forming tools in metal forming industries.Source Type:Article5 - Some of the metrics are blocked by yourconsent settings
Publication Access status: Metadata only , Surface roughness and coefficients of friction of 3D-printed clamp tools made from selective laser meltingThe practical use of 3D-printed metal tools in production industries requires accurate characterization of tool behaviour. In metal forming industries, the efficacy of clamp tools largely depends on surface roughness and friction behaviour of tool surfaces. This research is aimed to investigate surface roughness and friction behaviour of 3D-printed clamp tools made from selective laser melting process. Gas atomized powdered tool steel-X3NiCoTi1895 (EN 1.2709) is used to 3D print clamp tools. A mechanical setup determines the friction coefficients of 3D-printed samples under practical loading conditions. The effect of raster angle on surface roughness of 3D-printed clamp tools is determined. These findings serve as the basis of a broader project in which metal-3D-printed forming tools are developed and tested in actual production setups.Source Type:Article4 - Some of the metrics are blocked by yourconsent settings
Publication Access status: Open Access , Topology optimization of die geometry through identification of high pressure areas on die surface(2025); ; In profile bending of tubes, FE-simulations have shown that the contact between tool (die) and metal tube manifests a unique contact pressure pattern at the tool surface. In this study, practical sensors are employed to determine the pressure transmission from tube onto tool surface. The physical measurements provided by sensors showed high agreement with the FE-simulation. It is demonstrated that the pressure exerted by the tube is not transmitted uniformly throughout the tool surface rather it is localized towards centre and fringes. This investigation opens up the possibility to design tools (forming dies) using topology optimization. The topology optimized geometry of a tool results in substantial material savings within the tool geometry. This research paper demonstrates that the identification of pressure pattern on the tool surface provides the basis to design tools with bare essential material within the tool geometry, hence stepping forward towards cost effective manufacturing of tools.Source Type:Article8 31