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首页> 外文期刊>Journal of Materials Processing Technology >An innovative process combination of additive manufacturing and sheet bulk metal forming for manufacturing a functional hybrid part
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An innovative process combination of additive manufacturing and sheet bulk metal forming for manufacturing a functional hybrid part

机译：用于制造功能杂交部分的增材制造和薄层金属形成的创新过程组合

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The combination of additive manufacturing (AM) and forming offers new opportunities in part and process chain design. To show the potential of this process combination, a gear component with discrete tooth geometry is manufactured by powder bed fusion of metal using a laser beam (PBF-LB/M) and forming. Such gear components are manufactured conventionally in a process chain of several sheet bulk metal forming operations like orbital forming, deep drawing and upsetting. Orbital forming is used to manufacture a tailored blank to increase form filling in the subsequent forming operations. However, challenges are form filling and control of material flow. These severely affect whether the target geometry can be realized. To overcome these limitations, in this work PBF-LB/M is used to manufacture the tooth geometry close to the target on a flat sheet. Subsequently, the three-dimensional part geometry is realized by forming. The advantage is that the orbital forming step is not necessary. With that, the tooth geometry does not depend on material flow. A further benefit is geometric flexibility of additive manufacturing processes. Hence, diversity of variations can be increased over a wide range without additional cost intensive forming tools for each single part geometry. Besides, the potentials and challenges of the approach are discussed. The investigations include characterization of formability of sheet metal and AM material, metallographic analysis and hardness measurement. A process chain for manufacturing hybrid parts is presented and the final part geometry is evaluated by topography measurement. The major finding is that the tooth geometry manufactured by additive manufacturing and forming is closer to the target than for the conventional process chain. Additionally, a comparison of technological and economic advantages is drawn. Finally, an extension of the approach is presented by hybrid parts with additively manufactured structures on both sides of the sheet metal.
机译：添加剂制造（AM）和成形的结合为零件和工艺链设计提供了新的机会。为了展示这种工艺组合的潜力，采用激光束（PBF-LB/M）和成形技术，通过金属粉末床熔合来制造具有离散齿几何结构的齿轮组件。这种齿轮部件通常在多个板材整体成形操作（如轨道成形、拉深和镦粗）的工艺链中制造。轨道成形用于制造定制坯料，以增加后续成形操作中的填充量。然而，挑战在于表单填充和物流控制。这些严重影响目标几何体能否实现。为了克服这些局限性，在这项工作中，PBF-LB/M用于在平板上制造接近目标的齿形。随后，通过成形实现三维零件几何。优点是不需要轨道形成步骤。这样，齿的几何形状就不依赖于材料流动。另一个好处是添加剂制造工艺的几何灵活性。因此，可以在很大范围内增加变化的多样性，而无需为每个单个零件几何体使用额外的成本密集型成形工具。此外，还讨论了该方法的潜力和挑战。研究包括金属板材和AM材料的成形性表征、金相分析和硬度测量。提出了一种制造混合零件的工艺链，并通过形貌测量对最终零件的几何形状进行了评估。主要发现是，与传统工艺链相比，通过添加制造和成形制造的齿形更接近目标。此外，还对技术和经济优势进行了比较。最后，通过在金属板两侧添加制造结构的混合零件，提出了该方法的扩展。

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