Dimensional precision and wear of a new approach for prototype tooling in deep drawing

Abstract

In this work, we present and evaluate a new approach for prototype tooling in deep drawing based on direct polymer additive tooling. With fused filament fabrication (FFF) a PLA shell is printed additively. Afterwards, this is filled with ultra-high performance concrete (UHPC). UHPC is characterized by its higher strength properties compared to conventional concrete materials, which makes the material feasible for forming applications. Two configurations of these hybrid UHPC polymer additive are possible: either the PLA shell is in contact with the sheet metal during forming or UHPC. The hybrid UHPC polymer additive tooling approach has the potential to be more cost-efficient for small series. The dimensional precision and wear of such hybrid tools is evaluated using a standard cup geometry. A test series of 30 cups with sheet metal DX56+Z with 1 mm thickness was drawn with the hybrid tools as well as with a polymeric tool and a conventional steel tool. The dimensional precision and wear of the prototype tools was evaluated optically.