RESEARCH ARTICLE

Hybrid forming mechanism of patternless casting and laser cladding

  • Zhongde SHAN ,
  • Fuzhen SUN ,
  • Yang LIU
Expand
  • China Academy of Machinery Science and Technology, Beijing 100044, China; State Key Laboratory of Advanced Forming Technology & Equipment, Beijing 100083, China

Received date: 14 Mar 2019

Accepted date: 11 Jun 2019

Published date: 15 Dec 2019

Copyright

2019 Higher Education Press and Springer-Verlag GmbH Germany, part of Springer Nature

Abstract

In accordance with the requirement of manufacturing dies quickly and economically, a hybrid forming method of stamping dies for automobile panels is proposed. The method combines digital patternless casting and high-power laser cladding. An experimental study is conducted on the hybrid forming process and its trial production and application in the manufacturing of stamping dies for typical panels. Results prove that the laser cladding layer exceeds HRC60 (Rockwell hardness) and thus meets the production efficiency requirement of automobile dies. The rate of defects is well controlled. Compared with traditional technology, this technology has remarkable advantages and advancement.

Cite this article

Zhongde SHAN , Fuzhen SUN , Yang LIU . Hybrid forming mechanism of patternless casting and laser cladding[J]. Frontiers of Mechanical Engineering, 2019 , 14(4) : 393 -401 . DOI: 10.1007/s11465-019-0550-1

Acknowledgement

This study was supported by the National Science Fund for Distinguished Young Scholars (Grant No. 51525503).
1
Zhang Y, Wu L M, Guo X Y, . Additive manufacturing of metallic materials: A review. Journal of Materials Engineering and Performance, 2018, 27(1): 1–13

DOI

2
Le V T, Paris H. A life cycle assessment-based approach for evaluating the influence of total build height and batch size on the environmental performance of electron beam melting. International Journal of Advanced Manufacturing Technology, 2018, 98(1‒4): 275–288

DOI

3
Zhang W. Research on microstructure and property of Fe-VC composite material made by laser cladding. Physics Procedia, 2012, 25: 200–204

DOI

4
Gao W Y, Chang C, Li G, . Study on the laser cladding of FeCrNi coating. Optik, 2019, 178: 950–957

DOI

5
Cordero Z C, Dinwiddie R B, Immel D, . Nucleation and growth of chimney pores during electron-beam additive manufacturing. Journal of Materials Science, 2017, 52(6): 3429–3435

DOI

6
Fuchs J, Schneider C, Enzinger N. Wire-based additive manufacturing using an electron beam as heat source. Welding in the World, 2018, 62(2): 267–275

DOI

7
Markl M, Ammer R, Rüde U, . Numerical investigations on hatching process strategies for powder-bed-based additive manufacturing using an electron beam. International Journal of Advanced Manufacturing Technology, 2015, 78(1‒4): 239–247

DOI

8
Hossain M S, Mireles J, Morton P, . Part re-registration during process interruption of electron beam melting additive manufacturing. International Journal of Advanced Manufacturing Technology, 2018, 96(1‒4): 337–344

DOI

9
Wang Y H, Chen X Z, Konovalov S V. Additive manufacturing based on welding arc: A low-cost method. Journal of Surface Investigation. X-ray, Synchrotron and Neutron Techniques, 2017, 11(6): 1317–1328

DOI

10
Kim J, Lee W J, Park H W. The state of the art in the electron beam manufacturing processes. International Journal of Precision Engineering and Manufacturing, 2016, 17(11): 1575–1585

DOI

11
Shan Z D, Qin S, Liu Q, . Key manufacturing technology & equipment for energy saving and emissions reduction in mechanical equipment industry. International Journal of Precision Engineering and Manufacturing, 2012, 13(7): 1095–1100

DOI

12
Shan Z D, Dong X L, Liu F. Study on manufacturing of sand mold by direct milling. In: Proceedings of the 3rd Seminar of Sino-Korea Cooperation on the Advanced Manufacturing Technology. 2008, 165–169

13
Liu H M, Hu Z Q, Qin X P, . Parameter optimization and experiment study of the sprocket repairing using laser cladding. International Journal of Advanced Manufacturing Technology, 2017, 91(9‒12): 3967–3975

DOI

14
Li C, Yu Z B, Gao J X, . Numerical simulation and experimental study of cladding Fe60 on an ASTM 1045 substrate by laser cladding. Surface and Coatings Technology, 2019, 357(15): 965–977

DOI

15
Yu T B, Yang L, Zhao Y, . Experimental research and multi- response multi-parameter optimization of laser cladding Fe313. Optics & Laser Technology, 2018, 108: 321–332

DOI

16
Arias-González F, del Val J, Comesaña R, . Production of phosphor bronze coatings by laser cladding. Procedia Manufacturing, 2017, 13: 177–182

DOI

17
Juan Y F, Li J, Jiang Y Q, . Modified criterions for phase prediction in the multi-component laser-clad coatings and investigations into micro-structural evolution/wear resistance of FeCrCoNiAlMox laser-clad coatings. Applied Surface Science, 2019, 465(28): 700–714

DOI

18
Dobrzański L A, Bonek M, Hajduczek E, . Structure and properties of laser alloyed gradient surface layers of the hot-work tool steels. Journal of Achievements in Materials and Manufacturing Engineering, 2008, 31(2): 148–169

19
Gu D D, Ma C L, Xia M J, . A multiscale understanding of the thermodynamic and kinetic mechanisms of laser additive manufacturing. Engineering, 2017, 3(5): 675–684

DOI

20
Qvarnstrӧm H. Technical note: A mathematical formula for transformation between the steel hardness scales of Rockwell C and Vickers. Journal of Heat Treating, 1989, 7(1): 65–67 doi:10.1007/BF02833189

Outlines

/