Manufacturing of advanced smart tooling for metal forming

Evaluation of ionic liquids as lubricants in micro milling – process capability and sustainability

Manufacturing can be defined as the transformation of raw materials into desired products by various processes, such as machining, welding and coating. Today, laser and arc heat sources are largely used as the means for processing raw materials. The laser is one of the most widely used non-contact thermal energy sources in various processes, and the development of laser processes and devices for effective manufacturing is still ongoing. Arc heat sources are widely used in welding and coating processes. In particular, the types of welding processes using arc heat sources are very different depending on the materials used and the purpose of welding. In this paper, individual processes using laser and arc heat that have been reported over the past five years are reviewed, including machining, welding, sintering and coating. Then, hybrid processes that use laser and arc heat sources together are also reviewed. The final part of this review provides a summary and discusses future trends for individual and hybrid processes using laser and arc heat sources.

Laser and Arc Manufacturing Processes: A Review

A simplified analytical model is presented that predicts the depth progress during and the final hole depth obtained by laser percussion drilling in metals with ultrashort laser pulses. The model is based on the assumption that drilled microholes exhibit a conical shape and that the absorbed fluence linearly increases with the depth of the hole. The depth progress is calculated recursively based on the depth changes induced by the successive pulses. The experimental validation confirms the model and its assumptions for percussion drilling in stainless steel with picosecond pulses and different pulse energies.

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Analytical model for the depth progress of percussion drilling with ultrashort laser pulses

Blanking is one of the most frequently used manufacturing processes. Its profitability strongly depends on the development of tool wear, since this determines the decisive factors of part quality, process stability and service intervals. Reducing the wear can only be achieved by gaining a sufficient understanding of the interactions which cause it. One important factor in this context is the temperature increase in the shear zone due to the partial dissipation of inelastic work. The resulting temperature gradient in the tool, combined with the electric contact between the workpiece and the tool, generates thermoelectric voltages and currents. The thermoelectric currents are suspected to have an especially strong influence on adhesive wear, but the mutual correlation between them during blanking operations is not clear. Therefore, several blanking examinations were carried out with the aluminum alloy 5083. The thermoelectric currents and voltages were measured instantaneously in the tool and their impact on the development of wear was shown by externally manipulating the occurring thermoelectricity.

On the correlation between thermoelectricity and adhesive tool wear during blanking of aluminum sheets

In metal forming, lubricants are still used to prevent corrosion, to reduce friction, wear and tool load as well as to protect the workpieces and intermediates. In economic and ecological points of view, the challenge is the avoidance of lubricant usage. Within this article we define the term of dry metal forming, a technology which contributes an approach to establish green technology in mass production. Regarding this, the benefits of this technology are shown. Three different approaches exist to achieve a dry forming process: ceramic tools, self-lubricating coating systems and hard material coatings. Concerning this matter, the state of research in dry metal forming is reviewed within this paper.

/pdf/dry-metal-forming-definition-chances-and-challenges-1m7f5seivc.pdf

Dry metal forming: Definition, chances and challenges

Thermally joining of metallic joining parts (16) via non-contact heat input by laser beam welding, preferably laser beam deep penetration welding, comprises melting the joining parts along a predetermined joining line (25) by non-contact heat input and connecting the solidified melt with each other by a joining seam (26), where the melt is excited to mechanical vibrations in a targeted manner. An independent claim is also included for thermal joining seam, produced by the above method, comprising a charmed, globular grain structure.

Thermally joining of metallic joining parts via non-contact heat input by laser beam welding, comprises melting joining parts and connecting solidified melt by joining seam, where melt is excited to mechanical vibrations in targeted manner

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Dry metal forming: Definition, chances and challenges

Thermally joining of metallic joining parts via non-contact heat input by laser beam welding, comprises melting joining parts and connecting solidified melt by joining seam, where melt is excited to mechanical vibrations in targeted manner