open access publication

Article, 2024

Performance evaluation of polymer-filled metal fused filament fabrication tooling for profile extrusion

The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, 1433-3015, Volume 132, 7-8, Pages 3363-3378, 10.1007/s00170-024-13475-1

Contributors

Kain, Martin [1] Parenti, Paolo 0000-0001-5957-7507 [2] Annoni, Massimiliano Pietro Giovanni 0000-0002-5172-4282 [2] Calaon, Matteo 0000-0002-9437-9829 [1] Pedersen, David Bue 0000-0002-7013-7614 [1] Tosello, Guido 0000-0002-5071-7830 (Corresponding author) [1]

Affiliations

  1. [1] Technical University of Denmark
    2. [NORA names: DTU Technical University of Denmark; University; Denmark; Europe, EU; Nordic; OECD];
  2. [2] Politecnico di Milano
    3. [NORA names: Italy; Europe, EU; OECD]

Abstract

The application of additive manufacturing (AM) for tooling in the mould and die industry brings a disruptive potential in process performance, design flexibility and product enhancements. Maturing of existing AM technologies and emerging technologies such as metal-fused filament fabrication (metal FFF) can further support the applicability of AM tooling in polymer profile extrusion. This study provides a complete characterization of metal FFF 17–4 PH stainless-steel die inserts and evaluates their applicability in a polymer extrusion process chain. The presented experimental assessment pivots on the metrological characterization of the produced inserts and the impact of the insert characteristics on the final extrudates’ product. Considering a conventionally manufactured benchmark insert, produced via subtractive methods (CNC machining and electrical discharge machining), comparable results for AM tools in terms of extrudates’ quality and process repeatability are presented. It was found that despite significant higher average surface parameters for AM insert tools (Sa = 2–9 µm vs. Sa = 0.3–0.9 µm for dies manufactured by machining), a much smaller difference was observed in the resulting quality of polymer extrudates’ product. The roughness generation effect of polymer profile extrusion based on the different dies’ internal surface roughness topography and the effect on extrudates product was evaluated. Three-dimensional average roughness Sa on acrylonitrile butadiene styrene extrudate surfaces obtained from conventionally machined dies was in the range of 0.3 µm. For extrudates obtained from additively manufactured dies, their Sa was in the rage of 0.5 µm (despite the much higher surface roughness of FFF dies compared to machined dies). The results confirm that with suitable extrudates’ product requirement, it is feasible to apply metal FFF as the selected manufacturing method for tooling in polymer profile extrusion.

Keywords

AM technologies, AM tools, Convention, FFF, RAGE, SA, acrylonitrile, additive manufacturing, application of additive manufacturing, applications, average roughness Sa, chain, characteristics, characterization, design, design flexibility, die, die industry, die insert, disruptive potential, effect, enhancement, extrudate surface, extruded products, extruder, extrusion, fabrication, filament fabrication, flexibility, generation effect, impact, industry, insertion, insertion characteristics, insertion tool, manufactured die, manufacturing, manufacturing methods, maturation, metal, metal-fused filament fabrication, method, metrological characterization, mold, parameters, performance, performance evaluation, pivot, polymer, potential, process, process performance, process repeats, processing chain, production, production requirements, productivity enhancement, profile, profile extrusion, quality, range, repeats, requirements, results, rough topography, roughness, roughness Sa, study, subtraction method, surface, surface parameters, surface roughness topography, technology, tools, topography

Funders

  • Ministry of Education, Universities and Research

Data Provider: Digital Science

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