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Research on the redesign of precision tools and their manufacturing process based on selective laser melting (SLM)

Di Wang (South China University of Technology)
Changhui Song (Institute of Sports Medicine, Peking University Third Hospital)
Yongqiang Yang (South China University of Technology)
Ruicheng Liu (School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou, China)
Ziheng Ye (School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou, China)
Dongming Xiao (School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou, China)
Yang Liu (School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou, China)

Rapid Prototyping Journal

ISSN: 1355-2546

Article publication date: 18 January 2016

820

Abstract

Purpose

This paper aims to verify that additive manufacturing technology could be used for the redesign and rapid manufacturing of tools and determine whether the mechanical performance of such tools can satisfy the practical operating requirements.

Design/methodology/approach

A special key was selected as the research object in this paper. The special key was innovatively redesigned and manufactured directly using selective laser melting (SLM). The function and critical geometries of the special key were first analysed, which was followed by discussions on the geometrical constraints in the manufacturing of typical geometrical features using SLM technology. Next, the special key was redesigned based on the SLM geometrical constraints and the functional requirements. Finally, the key was manufactured using SLM, and the mechanical performance characteristics of the key were determined.

Findings

The minimal geometrical feature was 0.2 mm when manufacturing thin walls using SLM. The reliable building angle of an overhanging surface was 40°. The top surface quality of the part could be greatly improved through laser surface re-melting. The volume of the redesigned special key based on the SLM process was only one-third to one-fourth of the original key. The mechanical properties, such as tensile strength and micro-hardness, of the samples manufactured using SLM were able to reach the practical operating requirements.

Originality/value

It is completely feasible to redesign and manufacture precision tools based on the innovative approach of SLM. The advantages of the redesigned tools includes the lack of design restrictions that hinder traditional manufacturing methods, material savings, ability to produce tools that cannot be easily copied and rapid production speed for a small number of tools.

Keywords

Acknowledgements

The work described in this paper was supported by the National Natural Science Foundation of China (Granted No. 51275179), the Natural Science Foundation of Guangdong Province (Granted No. 2012040007516) and the Doctoral Scientific Fund Project of the Ministry of Education of China (Granted No. 20120172120006).

Citation

Wang, D., Song, C., Yang, Y., Liu, R., Ye, Z., Xiao, D. and Liu, Y. (2016), "Research on the redesign of precision tools and their manufacturing process based on selective laser melting (SLM)", Rapid Prototyping Journal, Vol. 22 No. 1, pp. 104-114. https://doi.org/10.1108/RPJ-02-2014-0021

Publisher

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Emerald Group Publishing Limited

Copyright © 2016, Emerald Group Publishing Limited

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