Page 42 - MetalForming August 2017
P. 42

Add AM to Your Arsenal
 jigs and fixtures, but for metalforming tools as well. This often happens when metalformers need to prove out tool- ing, can’t wait for traditional tool-build methods or see the benefits of eco- nomical low-volume production.
Hydroforming and stretchforming, notes Wild, are two proven applica- tions for tooling, including punches, pressure intensifiers, matched male and female tools, and back-filled tools.
In tests by Stratasys with industry part- ners, Wild reports success in using Ultem 9085 or Nylon 12CF on Stratasys Fortus 3D-printing systems to produce low-volume or bridge tooling in form- ing applications. These tools, she says, have been validated for forming pres- sures to 15 ksi in runs to 100-plus parts.
FDM was used to produce a 10 by 13 by 2.5-in. stretchforming tool with
multiple contours, made with Ultem 9085 material. The tool, according to Wild, successfully formed an aluminum alloy, 2024-0, in thicknesses from 0.050 to 0.100 in. This is an optimal applica- tion, she says, because surface pres- sures are minimal, and the tool can be easily optimized to minimize build times and cost.
The same material with FDM was employed to produce insert tooling in a tube-hydroforming application. With internal pressure ranging from 3 to 15 ksi, the tooling formed 16- gauge 1008 carbon steel, as a 2-in.- dia. tube, in 13 forming cycles. This tooling is best-suited for minimal- deformation operations, reports Wild. High-deformation operations would require consideration of localized stress concentrations.
And, for rapid repairs, The U.S. Navy has employed the FDM AM process to produce a variety of simple polycar- bonate forming tools. Navy officials say the process has allowed for the return of aircraft to service (after part fractures due to hard carrier landings, for example) in a fraction of the time as compared to traditional tool-and- part-production processes.
Again, across all of these examples, printed tooling yields significant lead- time savings as well as customized and economical low-volume production. Important factors to consider when researching the resin-tooling route: forming pressures, quantity of parts needed and type/thickness of the metal to be formed.
Taking the Next Step
Okay, so all of the above has con- vinced you that AM can serve valuable functions in your operations. What now?
“The AM landscape is dotted with organizations to help you travel the 3D-printing path,” says Wild. “An exam- ple is Stratasys’ Expert Services Group, which can create CAD designs and per- form other services. It can take your file of a fixture or tool, redesign it for AM and even build it while walking you through the entire process. Service
for stamping presses
           Optimize your press, with Hilma ball or roller lifters, for safe, easy die handling.
Consult with Hilma to customize a die change system to suit your needs.
 Hydraulic or Mechanical
 Roller or Ball Type
 Robust Steel Bars
 Cartridge Inserts or Rollblock Bar
 Standard or
High Temperature
               Booth A5319
Fenton, MO 63026 Carr Lane Roemheld Mfg. Co. (636) 386-8022
               40 MetalForming/August 2017

   40   41   42   43   44