Development of cold forming dies by hybrid additive laminated tooling

 Hybrid additive manufacturing (AM) combines conventional processes with AM to overcome their limitations. In hybrid laminated tooling, sheet lamination is combined with direct energy deposition: the tool core is built from sheet laminates, while laser metal deposition with post-processing reduces the stair-step effect. This approach lowers manufacturing costs and enables complex geometries in short time. In cooperation with fischerwerke, this transfer project applies knowledge from deep drawing tools to cold forging tools, where loads and requirements differ. The goal is to define the physical limits of the concept using finite element simulations for tool design. Input requires characterization of both deposited material and sheet metal. The impact of post-processing methods such as laser polishing, ball burnishing, and milling on surface roughness will be assessed to identify the most feasible option. Finally, the wear resistance and fatigue strength of hybrid cold forging dies will be evaluated under production conditions.

Dardaei Joghan, H., Hahn, M., Weinert, F. Korkolis, Y.P., Tekkaya, A.E., 2025, Effect of Ball Burnishing and Laser Polishing on the Surface Characteristics of Deposited Layers in Hybrid Additive Laminated Tooling, MSEC conference from April 23 – 27 in Greenville, South Carolina, USA. https://doi.org/10.1115/MSEC2025-151342

Dardaei Joghan, H., Agboola, O., Tekkaya, A.E., 2024. Realization of functionally graded components with an optimized hybrid additive laminated tooling method, Materials Research Proceedings, Vol. 41, pp 80-89. https://doi.org/10.21741/9781644903131-9

Dardaei Joghan, H., Hahn, M., Aboola, O.E., Tekkaya, A.E. 2023. Resources and manufacturing technology evaluation of hybrid additive metal laminated tooling for forming. Materials Research Proceedings, vol. 28.

 http://dx.doi.org/10.21741/9781644902479-3

Dardaei Joghan H., Hölker-Jäger R., Komodromos A., Tekkaya A.E. 2023. Hybrid additive manufacturing of forming tools. Special Issue on Automotive Innovation. https://doi.org/10.1007/s42154-023-00239-y

Dardaei Joghan, H., Hahn, M., Sehrt, J.T, Tekkaya, A.E., 2022.  Hybrid additive manufacturing of metal laminated forming tools. CIRP Annals, vol. 71, pp. 225–228. https://doi.org/10.2370/9783844094817

 Dardaei Joghan, H., Hahn, M., Tekkaya, A.E., 2022.  Effect of preheating during laser metal deposition on the properties of laminated bending dies. Intern. Journal of advanced manufacturing technology, vol. 125, pp. 157-168. http://dx.doi.org/10.1007/s00170-022-10697-z