Design, performance, and cost savings of using GF-PC additively manufactured tooling for stamping of HSS 590 sheet metal

Athale, Madhura; Park, Taejoon; Hahnlen, Ryan; Pourboghrat, Farhang

doi:10.1016/j.jmapro.2023.05.072

Design, performance, and cost savings of using GF-PC additively manufactured tooling for stamping of HSS 590 sheet metal

Journal Article · Wed Jun 07 00:00:00 EDT 2023 · Journal of Manufacturing Processes

DOI:https://doi.org/10.1016/j.jmapro.2023.05.072· OSTI ID:2418838

Athale, Madhura ^[1]; Park, Taejoon ^[2]; Hahnlen, Ryan ^[3]; Pourboghrat, Farhang ^[2]

The Ohio State Univ., Columbus, OH (United States); OSTI
The Ohio State Univ., Columbus, OH (United States)
Honda Development and Manufacturing of America LLC, Raymond, OH (United States)

Conventional sheet metal forming tooling in the automotive industry is made up of hardened steel and used for mass-production. Prototype tooling made of metal is durable, but it is only used for a small number of parts despite its high cost, contributing heavily to the vehicle development cost. Additive Manufacturing (AM) offers a low-cost alternative for fabricating tooling suitable for low-volume production. Here, this study investigates the feasibility of using AM polymer composite tooling for the stamping of 1.5mm thickness HSS 590 steel sheets through a two-pronged approach – experimental and numerical analysis. Sheet metal stamping experiments were conducted with glass fiber reinforced polycarbonate (GF-PC) AM polymer tooling and their performance was evaluated based on various metrics such as tool deformation and part accuracy. Finite element simulations of the stamping process were performed, which accurately captured the tool deformations seen in experiments with the use of anisotropic material models. The effective use of simulations in optimizing process parameters to achieve the desired final part geometry is also demonstrated. The GF-PC AM polymer composite tooling was found to be well suited for low volume production applications with potential cost savings.

View Accepted Manuscript (DOE)

Research Organization:: Clemson Univ., SC (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE); USDOE Office of Science (SC), Basic Energy Sciences (BES)

Grant/Contract Number:: EE0010203; SC0023389

OSTI ID:: 2418838

Alternate ID(s):: OSTI ID: 1984553

Journal Information:: Journal of Manufacturing Processes, Journal Name: Journal of Manufacturing Processes Journal Issue: C Vol. 101; ISSN 1526-6125

Publisher:: Society of Manufacturing Engineers; ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
3D printing
Additive Manufacturing (AM)
Anisotropy
Finite Element Analysis (FEA)
Mechanical testing
Sheet metal forming

Design, performance, and cost savings of using GF-PC additively manufactured tooling for stamping of HSS 590 sheet metal

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