Development of cold forging dies by hybrid additive laminated tooling

• Applicant: Professor Yannis Korkolis, Ph.D.
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: since 2025
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 553624967

Hybrid additive manufacturing allows conventional processes to be combined with additive manufacturing to overcome the limitations of each process. Hybrid additive laminated tooling for forming combines sheet lamination with direct energy deposition, where the core of the tool is made from sheet laminates and laser metal deposition where post-processing is used to reduce the stair-step effect. This method not only reduces manufacturing costs, but also helps to produce complex geometries in a short time. In this transfer project, in cooperation with fischerwerke, the knowledge gained from deep drawing tools will be transferred to cold forging tools, where the tool loads and requirements are different. The aim of the project is to determine the physical limits of the proposed concept. The finite element method will be used to determine the process limits for tool design. As input for the numerical analysis, the deposited material and the used sheet metal have to be characterized. The effect of the combination of different post-processing methods such as laser polishing, ball burnishing, and milling on the surface roughness of the deposited areas will identify the most feasible method. The wear resistance and fatigue strength of hybrid cold forging dies will be evaluated under mass production conditions. Finally, the technological evaluation of the new hybrid cold forming process will be performed.

• DFG Programme: Research Grants (Transfer Project)
• Application Partner: Fischerwerke GmbH & Co. KG
• Co-Investigators: Dr.-Ing. Marlon Hahn; Professor Dr.-Ing. A. Erman Tekkaya