Process model for the tool-free production of metallic components with the Arburg Freeforming Process

• Applicant: Professor Dr.-Ing. Jürgen Fleischer
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: from 2015 to 2019
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 274091127

The Project Process model for the tool-free production of metallic components with the Arburg Freeforming Process will expand the conventional tool based Metal Injection Molding (MiM) process, through the use of a metal Feedstock along with the Arburg Freeforming Process, to a flexible MIM Process. This presents a new, flexible approach for the generative production of metallic components. Due to high similarities to the conventional injection molding process it has a high capability in terms of component quality (shape-persistence and mechanical properties). Additionally it has high economic potential due to the absence of shaping molds. On the basis of the novelty of the Arburg Freefoming Process, the process has yet to be examined and there are no recommendations as to a process design or model. In order to harness the available potential, the influences and interactions of materials, process and nozzle geometry parameters have to be statistically evaluated through a design of experiments (DoE). The approach target is to evaluate the flexible MIM process for the production of metallic components from the material 17-4PH, which is regarded as representative due to its widespread use in industry. By means of this experimentation a process model should be developed. Alongside will be evaluated two sequential series of experiments each with different sample geometries. In the first series of experiments the influence and interaction of materials, process and nozzle geometry parameters on the outcomes of dimensional stability (dimensional stability, flatness, roughness) and mechanical properties (tensile strength, hardness, density) will be determined based on tensile specimens and cubes. These geometries have simple geometry specifications (no complex transitions) and therefore allow the detection of mechanical characteristics (e.g. tensile strength, density) for creating a basic process model. In the second test based on a complex geometry, a gear which has complex geometry specifications (tooth flank curves), the existing process model will be validated (investigation of previous variables) and enhanced (investigation of new variables: dimensional tooth flank curves). The choice of factor levels for the parameters to be varied will be derived from the results of the first test series. A result should not only include descriptive process model equations for the flexible MIM process but also recommendations for materials, process and nozzle geometry parameter choices for future applications and materials. The expected results will form the basis for process understanding and process optimization, which will ultimately be reflected in a high component quality.

• DFG Programme: Research Grants