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© Fraunhofer IWU
Workshop 3
CONFORMAL COOLING WITH AM
Dr.-Ing. Bernhard Mueller Fraunhofer Institute for Machine Tools and Forming Technology IWU Head of Department Additive Manufacturing
Additive Manufacturing: Ready for the Future? Innovative Solutions for Lightweight Design and Digital Manufacturing, TraCLight (Transatlantic Cluster for Lightweighting) International Workshop, Waterloo (Canada), September 28, 2017
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Fraunhofer IWU Additive Manufacturing@Fraunhofer IWU Dresden – fields of work
tool making
functional integration in molds and dies for improved thermal management, output, part quality, tool life and process control
medical technology / implants
patient-specific design, surface structures for improved osseointegration, volume structures for stiffness adjustment, integration of sensors and actuators
process development
qualification of new materials, quality management, process simulation, heat treatment
AM specific component design, manufacturing and validation
process engineering, lightweight design,…
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Source: Roland Berger Strategy Consultants
Status quo of industrial application Market volume per industrial sector
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Series production of
Small batches
Spare parts
Assembling aids
Fixtures and tools
Today Tomorrow In Future
Prototypes
Pre-series parts
Small batch production for a few very selected parts
First tooling applications (particularly for plastics injection moulding)
Wide use for the production
Individual parts
Assembly groups
Tooling
Status quo of industrial application Future prospects of Metal Additive Manufacturing
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more available Materials : CoCr, 17-4 PH, AlSi12, Hastelloy X
Characteristic values acc. to: 1 VDI 3405 Blatt 2 2VDI 3405 Blatt 2.1 3 VDI 3405 Blatt 2.2 WIP 4VDI 3405 Blatt 2.x in prep.
Additive Manufacturing for Tooling Materials & mechanical properties (tool steels)
Material Condition Tensile
strength Rm [MPa]
Yield strength
Rp0,2 [MPa]
Elonga-tion
A [%]
Hardness
Modulus of elasticity
[GPa]
Tool steel 1 1.2709 X3NiCoMoTi 18 9 5
heat treated (490 °C)
2,040 - 2,180 1,870 - 1,940 3 - 5 54 - 56 [HRC]
Tool steel (stainless) Corrax®
heat treated (525 °C)
1,700 1,600 > 2 48 - 50 [HRC]
stainless steel 1.4404 X2CrNiMo 17-12-2
as build 640 500 > 15 20 [HRC]
Titanium 4
3.7165 TiAl6V4
heat treated 950 - 1,250 800 - 1,100 10 - 20 32 - 36 [HRC]
Aluminium 2
3.2381 AlSi10Mg
as build annealed
T6 heat treated
353 - 482 221 - 260 281 - 320
210 - 295 126 - 160 222 - 262
2 - 7 10 - 18 5 - 10
95 - 119 [HB] 63 - 74 [HB] 85 - 101 [HB]
67 - 78 57 - 73 69 - 80
Inconel 718 ³ 2.4668 NiCr19NbMo
as build annealed
T6 heat treated
929 - 1,308 896 - 1,080
1,334 - 1,545
583 - 945 549 - 922
924 - 1,278
20.2 - 32.7 31.9 - 42.2 6.6 - 19.4
280 - 395 [HV 10] 273 - 320 [HV 10] 453 - 485 [HV 10]
128 - 232 142 - 257 149 - 242
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Source: Bego
Q
Schmiedeteil
Kühlung
S
Q =ΔTemp. · λ · A
SQ =
ΔTemp. · λ · A
S
konturnahe Kühlung
WärmeleitfähigkeitKühlmedium
Formteil
Q
Schmiedeteil
Kühlung
S
Q =ΔTemp. · λ · A
SQ =
ΔTemp. · λ · A
S
konturnahe Kühlung
WärmeleitfähigkeitKühlmedium
Formteilcomponent
cooling system
conformal cooling
thermal conductivity
cooling medium
Added Value of using AM for tooling applications Tooling: Thermal management - conformal cooling
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Added Value of using AM for tooling applications Thermal management – types of cooling circuits
serial cooling circuit
parallel cooling circuit
panel cooling
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Milled base-body with drilled cooling channels (rough
machining)
CAD model of conformal cooling channels
1. grinded 2. blasted
Preparation of the compound surface
Aligning and positioning in the laser melting machine
Laser melting system ready for start of building process
Tooling insert with conformal cooling channels ready for
finish machining
Added Value of using AM for tooling applications Hybrid manufacturing (conventional base – AM top section)
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Added Value of using AM for tooling applications Thermal management – panel cooling
CFD simulation for panel cooling design mandatory
inlet
outlet
inlet
outlet
CAD flow temperature distribution
dead leg / hot spot
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Added Value of using AM for tooling applications Cost benefits
costs
production costs
AM tool
conventional tool
tool costs
cycle time reduction increase in part quality functional integration tailored part properties
part output
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AM for tooling Project examples from different manufacturing processes
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Project examples by manufacturing processes
manufacturing processes (DIN 8580)
primary shaping
plastic injection molding
high pressure light metal die
casting
secondary shaping / forming
sheet metal forming
cold sheet metal forming
hot sheet metal forming
bulk metal forming
(hot forging)
cutting joining coating changing material
properties
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Project examples by manufacturing processes
manufacturing processes (DIN 8580)
primary shaping
plastic injection molding
high pressure light metal die
casting
secondary shaping / forming
sheet metal forming
cold sheet metal forming
hot sheet metal forming
bulk metal forming
(hot forging)
cutting joining coating changing material
properties
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Project examples by manufacturing processes Plastic injection molding – cover for electric device
results:
reduction of cooling time (hold time) by 33 % (from 18 to 12 s)
reduction of cycle time by 19 % (from 31,4 to 25,3 s)
reduction of injection time and pressure by 5 % each
nach 5 Sekunden
nach 10 Sekunden
88 °C 25 °C
87 °C 15 °C
conventional tool AM tool
panel cooling system
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Project examples by manufacturing processes Plastic injection molding – cover for electric device
results:
better dimensional accuracy
conventional tool AM tool 18 s cooling time
12 s cooling time
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Project examples by manufacturing processes
manufacturing processes (DIN 8580)
primary shaping
plastic injection molding
high pressure light metal die
casting
secondary shaping / forming
sheet metal forming
cold sheet metal forming
hot sheet metal forming
bulk metal forming
(hot forging)
cutting joining coating changing material
properties
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Project examples by manufacturing processes High pressure light metal die casting – engine bed plate
initial situation:
local porosity at oil filter housing
within bed plate of a V8 engine
© DGH Group
© DGH Group
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design of an die insert with conformal cooling system
use of thermal and mechanical FEA for the design of the cooling system
minimum distance to the die surface
evaluation of different concepts of cooling systems (serial and parallel cooling)
Project examples by manufacturing processes High pressure light metal die casting – engine bed plate
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Project examples by manufacturing processes High pressure light metal die casting – engine bed plate
results:
die insert with conformal cooling system
reduction of scrap rate by more than 50 %
cycle time reduction by 3 %
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Project examples by manufacturing processes
manufacturing processes (DIN 8580)
primary shaping
plastic injection molding
high pressure light metal die
casting
secondary shaping / forming
sheet metal forming
cold sheet metal forming
hot sheet metal forming
bulk metal forming
(hot forging)
cutting joining coating changing material
properties
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typical material: 22MnB5
Yield strength (Rp0,2): 950 - 1,250 MPa
Tensile strength (Rm ): 1,300 - 1,650 MPa
Elongation (A5): 6 %
Hardness (HV10): 400 - 520
tailored material properties within one component become possible
areas of local strength and areas of high ductility
typical application: B pillar in car bodies component of high strength with high crash-absorbing capacity at the transitions to chassis and roof
Source: Volkswagen AG, Kassel
Project examples by manufacturing processes Hot sheet metal forming – material
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Project examples by manufacturing processes Hot sheet metal forming – project HiperFormTool
Manunet project “HiperFormTool”
increasing the performance of three sheet metal forming technologies (deep drawing, stretch forming and hot sheet metal forming) by AM tooling
added value and integration of additional functionalities
depending on target application cooling, heating, lubrication and sensor integration
Re-cooling additively manufactured tool punch
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process analysis and optimization through simulation
development of an innovative temperature control system for all tool components
improved process conditions and reduced cycle time
Assembly with innovative cooling system (CAD model)
temperature distribution conventional cooling system
temperature distribution additive cooling system
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Project examples by manufacturing processes Hot sheet metal forming – project HiperFormTool
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Temperature distribution of the component (3 s holding/ cooling time)
Tmax = 175 °C
14
forming trials
different holding/cooling times (10s, 8s, 5s, 3s)
10 s is currently state of the art
documentation of part temperature using thermal imaging
documentation of tool temperature using thermocouple and thermal imaging
significantly reduced holding/cooling time from 10 to 3 seconds
Project examples by manufacturing processes Hot sheet metal forming – project HiperFormTool
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Project examples by manufacturing processes
manufacturing processes (DIN 8580)
primary shaping
plastic injection molding
high pressure light metal die
casting
secondary shaping / forming
sheet metal forming
cold sheet metal forming
hot sheet metal forming
bulk metal forming
(hot forging)
cutting joining coating changing material
properties
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motivation:
high thermal-mechanical friction low tool life
reduction of thermal wear through improved thermal management
Project examples by manufacturing processes Bulk metal forming (hot forging) – piston
die with conventionally deep drilled cooling channels
die with conformal cooling channels
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results:
significantly less wear
gained part output by 17,5 %
Project examples by manufacturing processes Bulk metal forming (hot forging) – piston
wear after 6855 forgings wear after 5836 forgings
conventional tool AM tool 1.2367 1.2709
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Let’s get started!
Workshop 3 “Conformal Cooling with AM” Questions to be discussed
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Where do you see potential benefits of conformal cooling? (Cycle time? Part quality? Tailored part properties? Else?)
cycle time!
part quality!
Workshop 3 “Conformal Cooling with AM” Questions to be discussed
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How to work out a business case between the poles of manufacturing company, tool shop and (OEM) customer? Who pays (extra tooling cost)? Who earns (savings in manufacturing)?
need for AM? if yes, OEM to pay
win-win-win-situation
mfg. co. benefits most – willing to pay! tell OEM before
compensation between involved parties
differences in cost from buyer to payer
convincing OEMs to invest
Workshop 3 “Conformal Cooling with AM” Questions to be discussed
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What is your opinion on material (tool steel types)? Which properties do you need or expect? Are you fine with maraging steel or do you prefer conventional steels (H11/H13, 1.2367) or other tool materials (e.g. case-hardening steels)?
thermal expansion!
die life
thermal conduction (conductivity)
coatings to be applied (e.g. MMC)
softer core, hard (wear resistant) surface
Workshop 3 “Conformal Cooling with AM” Questions to be discussed
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Which manufacturing process would you like to improve? Injection molding? Die casting? Metal forming? Others (e.g. Extrusion)?
die casting
injection molding
blow molding
biodegradable plastics processing (quick cooling needed)
Workshop 3 “Conformal Cooling with AM” Questions to be discussed
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Are further mold & die functionalization opportunities beyond conformal cooling like venting, lubrication or sensor integration intriguing to you or rather overwhelming?
sensor integration!!
Workshop 3 “Conformal Cooling with AM” Questions to be discussed
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How do processes and operations have to changes to succeed with conformal cooling?
Include all stakeholders (tool designer, tool shop, customer, …)!
Allow freedom (time) to appointed key people to get it implemented!
Involve outside experts!
Develop an implementation plan!
Define your goals and monitor them!
Workshop 3 “Conformal Cooling with AM” Questions to be discussed
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Which gaps do you expect to be closed before (full scale) adoption of conformal cooling?
case studies published incl. proven die life
Workshop 3 “Conformal Cooling with AM” Questions to be discussed
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Thank you for your participation!
contact details: Dr.-Ing. Bernhard Mueller Fraunhofer IWU, Noethnitzer Str. 44, 01187 Dresden (Germany) phone: +49 351 4772-2136 e-mail: [email protected]
