Enabling the ARBURG Freeforming process for industrial production of metallic components

• Applicant: Professor Dr.-Ing. Jürgen Fleischer
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing ; Automation, Mechatronics, Control Systems, Intelligent Technical Systems, Robotics ; Engineering Design, Machine Elements, Product Development ; Production Automation and Assembly Technology
• Term: from 2020 to 2022
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 443103294

• Final Report Year: 2023

Final Report Abstract

In this project, the industrial improvement of the ARBURG Freeformer for the production of metal parts was achieved. The focus was on reducing wear and tear on the system and achieving a consistent volume output by means of an optimized control system. In the first phase, a comprehensive requirement analysis was carried out, which led to the qualification of a compatible feedstock made of 316L. Subsequently, concepts for the modification of the discharge unit were developed in order to increase the service life through different surface coatings. A system and process model considering the material viscosity was created. For this purpose, several zones in the unit were modeled and a relationship between mass pressure and volume flow was established. Based on the model, fluid simulations were carried out to analyze the behavior of the melt in the discharge unit. Another element was the design of an optimized control system in MATLAB Simulink, focusing on the dynamic control of the mass pressure generation in the discharge unit for a more robust volume flow. High-frequency pressure measurement in the nozzle was made possible by the use of optical pressure sensors, which were integrated into the control system. Finally, life cycle tests were carried out on improved prototypes of the discharge unit and complex demonstrators were manufactured using optimized manufacturing parameters.

Publications

• Additive manufacturing of metal components with the ARBURG plastic freeforming process. CIRP Annals, 67(1), 225-228.
  Spiller, Quirin & Fleischer, Jürgen
  
• “Investigations for the Optimization of MetalFreeforming using the ARBURG freeformer”, Solid Freeform Fabrication 2022: Proceedings of the 33rd Annual International Solid Freeform Fabrication Symposium – An Additive Manufacturing Conference. Austin, Texas, USA.
  Krischke, N.; Friedmann, M.; Fleischer, J.