Laser applications enable new tool and die features

Laser applications in
tool and die making

How light can enable new product features

Kristian Arntz
Fraunhofer IPT, Aachen, Germany

International Seminar: Application of new technologies
in the metal mechanic sector
Joinville, Brazil, September 2011
© WZL/Fraunhofer IPT

Laser applications in tool and die making
Presentation outline
1 Using light for production – Lasers as flexible production systems

2 Surface structures – ablating material to generate design features

3 Wear resistance – modifying material properties for better tool lifetime

4 Generating parts – Additive manufacturing for functional moulds

5 High strength materials – enhancing machining capability by laser softening

6 Outlook – how Lasers will contribute to future process chains

© WZL/Fraunhofer IPT Seite 1

What differentiates laser light from white light?
Properties of white light Properties of laser light
n polychrome, light with different wavelengths / n monochrome, light of a single wavelength /
frequencies frequency
n Low coherence, short wave trains n High coherence, long wave trains

n High divergence, broad diffusion, difficult to be n Low divergence, nearly straight spreading,
focussed and low intensity easy to be focussed and high intensity

Laser source
LASERQUELLE

µm-area bis 1000 km


Primary process influencing factors
n Intensity distribution in working plane
Ú Intensity is depending on time P(t)
- Laser source and beam parameters
Intensity [W/cm²]
Ú Intensity distribution depends on geometry
I(x, y, z)
- Intensity distribution in primary beam (laser source)
- Beam caustics (result of optical system)
- Location (and orientation) of working plane
y [mm]
n Influencing time x [mm]

Ú Feed rate (cw- and pw-mode)

Ú Pulse duration (and form), Pulse frequency z-
(pw-mode)
Focal plane
Working plane
z+
cw: Continuous Wave Mode
pw: Puls Wave Mode


Beam guidance and formation
Laser source Beam guidance Strahlformung

Collimation Focussing Focal plane
Direct emission lense lense
Expansion
Rayleigh length
lense
Field depth

Mirrors

Fibre coupled Fibre optic
(up to 100 m)


Influence of intensity and processing time on process
characteristics

Heat influence zone
Melt
Metal steam
Ejected
material

Intensity ≥ 103 W/cm² ≥ 105 W/cm² ≥ 106 W/cm² ≥ 108 W/cm² ≥ 109 W/cm² ≥ 1011 W/cm²
Processing time s - ms ms ms - µs µs µs - ps ps - fs
n Heating n Melting n Melting n Evaporating n Evaporating n Sublimating
Result
n Melting n Evaporating n Sublimating
n Hardening n Hard brazing n Deep pene- n Drilling n Engraving n Texturing
tration welding
n Soft brazing n Welding
Processes n Cutting
n Deposition
welding

Any change in process and system parameters influencing the intensity and ist
distribution results in a considerable change of process characteristics and result!


Example laser hardening
1000 100 10 1 0,1 [K/s]
Principle 1200
1100
n Absorption of laser light at part‘s Laser beam
PL 1000
surface AC1 1100
n Heating up of near-suface areas MS homogene austenite

Temperatur
1000
inhomogene austenite
to the temperature of 900
austenitasation by heat Hardened area 800 Ferrit + Perlit + Austenit
conduction (depth d £ 1 mm) vW 700
Ferrit + Perlit
Bulk material 600
n Uench hardening by fast heat
conduction into the inner part‘s 0,1 1 10 100 1000 10000 [s]
area (formation of martensite) ZTA diagram Zeit

900
1200°C T [°C] Austenite [%] Martensite [%] 800
Advantages 700 F
Ac1 600
n High surface hardness with fine A P

Temperatur
100% 500
grained texture MS
400 Ms
n Local heat input only 300
B

Mf
200
n Low distortion
100
Heating Hold Cooling t [s] 760 533 200
n Now chilling liquid
0,1 1 10 100 1000 10000 [s]
ZTU diagram time


Laser beam structuring – an innovative process for surface structuring
The challenge of "surface decoration" for tool and die
manufacturers
Etching
n High manual effort
n Poor reproducibility
n Limited material range
© Eschmann Textures
n Restricted flexibility related to the structure design

Electroforming
n High manual effort
n Moderate reproducibility
n Poor flexibility
n No consistency of a (digital) data chain
© Galvanoform
n Limited material range

A wider scope related to the structure design, the increase of the
reproducibility and the reduction of the manual effort require innovative
solutions for the surface texturing in the tool and die manufacturing!


The laser beam as a "tool" – fast, flexible and precise
System setup

Pulsed laser
source Laser scanner
Dynamic beam expander

Telecentric
F-Theta lens

Work piece

Fraunhofer IPT


"Removal rate and surface quality" – process basics
n Use of pulsed laser sources
– Pico- and nanosecond laser
n Ablation with ps-laser (1 picosecond = 10-12 sec)
– Material removal by sublimation (multi-photon-absorption):
"Cold" ablation process => no thermal conduction
– Nearly all materials are processable
Fraunhofer IPT
– Removal of a small material volume by a single laser pulse
– No melt formation on the surface
n Ablation with ns-laser (1 nanosecond = 10-9 sec)
– Linear absorption
– Predominantly melt ablation:
Thermal process with melt formation
– Limited range of processable materials
– Removal of a large material volume by single laser pulse
– Low-cost laser sources


"Complex shaped surfaces" – machine tools and CAM-system

Work
3D-model
piece

Fraunhofer IPT

n Machining centers n Completely CAM-based tool path planning and
– Modified 5-axis- precision-machine tools process parameter selection
n 4 additional axes by beam guidance system n Simulation, analysis und optimization of tool paths
(x´, y´, z´ and c´-axis)
n Advantages
n Integrated laser sources
– Modular setup guarantees the transferability to industrial
– Picosecond laser (LUMERA Laser)
used CAM systems
– Nanosecond laser (EdgeWave)
– Simulation of the machine kinematics for collision
n Heidenhain 530i - control
monitoring between work piece and machine


Application example "free formed surface“ – tulip design
Work piece specification
n Demonstrator with an arched surface

n Basis material 1.2343 (X38CrMoV5-1)

n Quenched and tempered to 50 +2 HRC

Result
n Large-scale and seamless surface
Fraunhofer IPT structuring
n Laser structured area: 80 mm x 60 mm

n Maximum depth of structure: 150 µm

Fraunhofer IPT


Application example "injection mold" – free formed surface
n Injection mold

n Basis material 1.2343 (X38CrMoV5-1)

n Quenched and tempered to 50 +2 HRC

n Laser structured area:
Fraunhofer IPT 196 mm x 152 mm

Result
Fraunhofer IPT structuring
– Leather-grain K3A of the Volkswagen Golf
VI
Fraunhofer IPT – Hybrid-structure with micro- and macro
structures
– Geometrically defined pyramid structures
Fraunhofer IPT


Application example "injection mold" – airbag shock absorbing pad
n Injection mold for the sample production
of an airbag shock absorbing pad (VW
Golf VI)
n Basis material 1.2311 (40CrMnMo7)
n 240 mm x 130 mm x 240 mm

Fraunhofer IPT Result
n Laser structured area with a diameter of
175 mm
structuring with a smooth structure
transition
– Leather-grain K3A of the Volkswagen Golf
VI
Fraunhofer IPT – Design-triangle structure


Application example “mould ring" – Tool deairing
n Base material 1.2379
(X153CrMoV12)
n Part diameter:
55 mm
n Micro structure was
modeled in CAD
n Depth gradient of micro
structure:
10 µm to 200 µm
n Applied laser system
enables melt and burr free
manufacturing

Fraunhofer IPT


Local wear resistance – Laser as a flexible production tool
One “Tool“ – a variety of customized possibilities
n Laser hardening
Process principle

Laser

Powder
Gas n Laser cladding

Laser beam

Work piece Treated zone n Laser alloying

Laser feed
Feed rate
rate

n Laser dispersing


“Material and surface variety”: Process basics
n Fibre-coupled diode laser system
– Laserline LDF 400-5000
– Power output 5000 W
– Variable focusing of laser spot diameter from 0.8 to 3 mm

n Additive material
– Alloying/dispersing: WC-Co-Cr, VC, TiC as powder material
– Cladding: Stellite, similar material (powder or wire)
1000 HV 0,1 – Powder feeding is proceeded by a co-axial nozzle (optional
also sideways)
800
– Wire-feeding is proceeded using a sideward feeding system
600

42 HRC
400 45 HRC
53 HRC
n Process gas
56 HRC
200
– Argon
0,1 0,5 0,9 1,3 1,7 2,1 2,5
Dist ance f rom surf ace [mm]
– Supplied with the additive material


Challenge: Wear resistance within tool making
Forging dies for hot tooling
n Local crack formation due to variations in temperature
n Abrasive wear at edges

Die casting moulds
n Local fire crack formation
n Abrasive wear at edges, bars and within the inlet area

Dies and punshes for cold forming
n Fatigue fractures starting at surface
n Abrasiver wear

Injection moulds
n Abrasive wear at edges and junctions
n Importance of keeping the surface quality and geometry

Need for local enhancement of material properties and surface quality for
complex geometries in individual or small series production within tool
making!

“Complex geometries”: Machining system and CAM-system

n Integration of all components in a precise fixe n Complete CAM-integrated machining path
axis machining system planning and process parameterization
n Robust, enclosed machining system including n Simulation, analysis and optimization of
suction machining path and coating
n Using of all control functionalities and n Modularity ensures a transferability to
integration of laser features by interpolation customary CAM-systems
clock
n Simulation of machine kinematic for
collision monitoring of part and machine


CAx-Framework – Graphical User Interface (GUI)
Technology
n Graphical User Interface (GUI)
Active
Domain classes parameter
Graphic
for all processing steps
input
n Process-specific strategy options
n Intuitive guidance through menu
n User-defined parameter input
– Geometry, Strategy, Tool, Process etc.
n “Active Graphics” for ad-hoc visualization
of active input parameter
n Input status is signalized by set of “traffic
lights”
n Direct feedback and help texts for the user
n Bilingual implementation (German/English)

Status of
n Simplified and expert mode
Parameter
Parameters parameter
description
input


Automated laser surface treatment – Machining system Alzmetall
n Target
Machining system for 5-axes laser surface treatment of
parts to enhance the wear resistance
n Used processes
– Laser hardening, Laser remelting
– Laser alloying, Laser dispersing
– Laser cladding
n Technical specifications
– Gantry-Concept (5-Axes simultaneous)
– Traverse path X-,Y-Axis: 800 mm; Z-Axis: 600 mm
– Position accuracy 0.007 mm
n Rotary/ Tilting unit
– A-Axis tilting range ± 140°
– C-Axis turning range 360° (continuously)
– Turning table diameter 320 mm
n Fibre coupled diode laser system
n NC-Control Siemens SINUMERIK 840 D Solution Line


5-axis laser surface treatment – Movie of the process


Example of laser dispersing: Forging die “Pedal”
Specifications of the die
n Treatment of upper and lower die
n Base material 1.2344 (X40CrMoV5-1)
n 400 x 140 x 100mm³
n Conventional:
Gas nitriding (thickness: 0.2 mm)
n Innovative process chain:
Forged part Laser surface treatment Laser dispersing and nitriding

Result
n Conventional:
Lifetime 6000 parts
n Laser surface treated:
Lifetime 10800 respectively 11000 parts

Laser dispersed area of the
Increase in lifetime of about 80%
Use in application
die


Example of laser alloying: “Aluminum die casting tool”
Specifications of the die
n Treatment of Aluminum die casing inserts
n Base material 1.2343 (X38CrMoV5-1)
n Max. dimensions: 55 mm
n Conventional: gas nitriding
Surface which has to be n Innovative process chain:
treated Laser alloying and nitriding
Result
n Conventional:
Lifetime 5 000 parts
n Laser surface treated:
Lifetime circa 10 000 parts

Embedded insert of an
Increase in lifetime of about 100%
Laser surface treatment
Aluminum die casting tool


Generating parts – Additive manufacturing for functional moulds
Integrated deposition welding and milling
n Wire based technology

n Layer-by-layer generation of metallic parts in a
combination of wire deposition welding and HSC milling
n Integration of combined process into one machinning
system
n Post machining of every (n) layer offers the possibility to
utilise small milling tools and though highly precise
machining
n Technology can be transferred to specific needs in terms
of machining system and parts which have to be
manufactured


Tool repair
Initial situation
n Mould defect

Target
n New build up of defect ares

Solution
n Failure identification

n Design of welding and milling area 10 mm

n Generation of NC data Pre-milling and deposition welding Pre-machining
n Pre-machining by milling

n Laser wire deposition welding

n Post machining of contour

Aprroximated time frame
n Programming: ca. 2,5 h

n Manufacturing time: < 45 min


Tool modification
Initial situation
n Design change

Target
n Partly automated geometry
change
Solution
n Design of welding and milling area

n Generation of NC data
Application oif change Pre-machining of milling area


n Post machining of contour

n Programming: ca. 60 min

n Manufacturing time: ca. 30 min

Applied welding geometry Finished part


Tool build for filigree geometries
Initial situation
n Mould insert for injection moulding

n Base 50x50 mm²

Target
n Build up of geometry

Solution
n Splitting in base and build area 10 mm

n Generation of NC data Splitting in base and build area Splitting in base and build area


n Intermittent contour milling and
final post machining of contour
n Appr. 2 days for each part

Finished part Finished part


Additive Manufacturing of a Mock-up Compressor Blade
CAM-Module CAM-Module CAM-Module

Laser-additive
Laser-additive manufacture Optical measurement Digitized model Adaptive milling
manufactured
of compressor blade of compressor blade of the built-up blade for contouring
blade

“CAx-Framework“

Simulation Simulation Simulation
Module Module Module
Simulation of Simulation of Simulation of
laser scanning laser cladding re-contouring
process process process
Source: Fraunhofer ILT

Simulation Simulation Simulation
Screenshot Screenshot Screenshot

Laser-additive manufacture Laser Scanning Adaptive milling
Source: Fraunhofer IPT, Fraunhofer ILT 2011

CAx Solutions for Digital Measurements
CAM Solutions for Inline Metrology
n CAM module for inline metrology
– Toolpath planning for geometry acquisition using laser stripe sensors
§ For Coordinate Measurement Machine (CMM), robot or machine
tool integrated sensor
– Sensor calibration using adequate strategies
§ 3-axis, 3+2-axis, 5-axis
– Transformation and analysis of acquired geometry data
§ Specialized analysis functionalities e.g. for turbine blades
– Direct availability of acquired data in CAD/CAM system for subsequent
processes
– Parameterized internal sensor model to support a wide range of
sensors
n Machine tool integrated laser stripe sensor overcomes
disadvantages of measurements on CMM
– High data rate
– No transport time
– Decreased set-up time
– 5-axis measurements for best orientation of sensor to surface
– Single reference for measuring and machining – no need to apply fitting
functions

Source: Fraunhofer IPT / CAx-Technologies, Production Metrology 2011


Machine and Process Simulation
Machine Simulation
n Simulation of:
– Laser scanner path
– Milling machine
– Laser machine
– Coordinate Measuring Machine - CMM Simulation of machine tool
integrated scan system
n Simulation of CNC toolpath for cavity geometry
for:
– Laser scanning
– Rough and finish milling
– Milling to re-contour
– Laser cladding
Simulation of milling
n Benefits Simulation of laser systems
processes
– Decision making on choice of handling systems
– Simulation of toolpath for verification
– Simulation of machine kinematics for collision
detection of part and machine
Integration of material
– Material removal and tool-material-engagement removal and cutter
conditions engagement simulation

Source: Fraunhofer IPT / CAx-Technologies 2011


Laser-assisted cutting
Technical ceramics – Fields of application
Main fields of application for technical ceramics
Mechanical engineering Chemistry and process engineering
n Nozzles n Fillers
n Rolling elements n Liners
n Extruders n Tubes
n Rings n …
n Roller bearings

Pumps Motors / Turbines
n Bushings n Bushings
n Plungers n Plungers
n Sealings n Valves
n bush bearings n Roller bearings
n cylinders, … n Turbine wheels

Textile machinery Medical equipment
n Guiding elements n Globes
n Spinning elements n Globe seats
n Knifes n articular
n Nozzles components
n …


Technical ceramics – Application examples
Application Examples (by industry sector)
1 Drawing, cold forging Non ferrous metal forming

2 µm

Microstructure of a silicon nitride ceramic
Metal forming Mechanical engineering
Properties of Si3N4
– high strength and toughness
– high wear resistance
– good chemical resistance
– excellent thermal fatigue resistance
– low heat expansion


Machining of high-strength materials
Process characteristic
n Improved machinability of high-strength materials like titanium-,
nickel- and cobalt-based alloys as well as silicon nitride ceramics
by localized heating of the cutting zone

Advantages
n Efficient cutting of materials that are difficult to machine –
significantly higher cutting volumes and longer tool life times
n Considerably shorter manufacturing times and lower costs

n Elimination of cooling lubricants (dry machining)

n Geometrically flexible, economic manufacture of complex
components made from technical ceramics (silicon nitride
ceramics)
n Highly reproducible manufacturing quality due to very good
control of the laser source

Source: A. Monforts Werkzeugmaschinen GmbH & Co. KG (picture 1)


Tool turret with integrated laser beam guidance
n Flexibility: Any combinations of
– Laser-assisted cutting
– Conventional cutting
– Laser surface treatment (Hardening, …)
n Modularity
n Easy to handle
– Handling of optical tools without laser-specific skills possible
– Extremely short tool exchange and set-up times
– Laser integration does not restrict the original functionality of
the machine tool
n Robustness
– Wear-resistant
– Low-maintenance
n Retrofitting
– Easy retrofitting in conventional turning lathes possible


Machine tool with integrated laser beam guidance
Technical specifications
n 2-axes CNC-turning lathe
n Main- and opposed spindle
n Wear- and maintenance-free
hydrostatic guidance of
Z-axis
n Travel increments as low as
0,001 mm without stick-slip-
effects
n High stiffness and good
damping
n True running accuracy of
spindle: 0,003 mm
n Max. swing diameter over
cross slide: 280 mm
n Max. turning length: 600 mm
n Fibre-coupled diode laser
system

Source: A. Monforts Werkzeugmaschinen GmbH & Co. KG


Outlook and vision
Lasers in tool and die manufacturing can contribute to
n reduced processing time by developing intelligent machining and
processing strategies
n New functionalities by realising adapted and highly sophisticated
surface properties
n increased quality by realising local wear protection

The integration of laser systems in machine tools contributes
to
n the design of continous process chains including preliminary
work and finishing
n Specific setting of local material properties by automatically
combining different manufacturing processes
n New functionalisation concepts by using reasonable tool
materials combined with surface modifications


Your contact to Fraunhofer IPT
Dipl.-Ing. Kristian Arntz
Head of department Laser Materials Processing
Fraunhofer Institute for Production Technology IPT
Steinbachstraße 17, 52074 Aachen
Phone: +49 241 89 04-121
Mobile:+49 174 1902817
Fax: +49 241 89 04-6121
Mail: kristian.arntz@ipt.fraunhofer.de


Laser applications enable new tool and die features

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