Hybrid forming mechanism of patternless casting and laser cladding

doi:10.1007/s11465-019-0550-1

Front. Mech. Eng.

2019, Vol. 14

Issue (4) : 393-401 https://doi.org/10.1007/s11465-019-0550-1

RESEARCH ARTICLE

Hybrid forming mechanism of patternless casting and laser cladding

Zhongde SHAN(

), Fuzhen SUN, Yang LIU

China Academy of Machinery Science and Technology, Beijing 100044, China; State Key Laboratory of Advanced Forming Technology & Equipment, Beijing 100083, China

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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.

Keywords patternless casting laser cladding hybrid forming rapid tooling

Corresponding Author(s): Zhongde SHAN

Just Accepted Date: 21 August 2019 Online First Date: 10 October 2019 Issue Date: 02 December 2019

Cite this article:

Zhongde SHAN,Fuzhen SUN,Yang LIU. Hybrid forming mechanism of patternless casting and laser cladding[J]. Front. Mech. Eng., 2019, 14(4): 393-401.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-019-0550-1
https://academic.hep.com.cn/fme/EN/Y2019/V14/I4/393

Fig.1 Technological process of laser compound manufacturing for automobile dies.

Fig.2 Tensile test on standard samples. (a) Before the test; (b) after the test.

Tab.1 Tensile strength and shrinkage

Fig.3 Hardness test.

Fig.4 Layer of laser cladding. (a) Interface of the substrate and cladding layer; (b) metallographic organization of the cladding layer.

Tab.2 Data comparison between traditional method and laser hybrid forming

Fig.5 Trial laser hybrid forming of right-front shock absorber upper bracket drawing die. (a) Target digital model; (b) model resolution; simulation of (c) the casting process and (d) the solidification process; (e) upper and (f) bottom sand mold; (g) substrate and (h) laser cladding; (i) hardness test; (j) penetrant inspection; (k) crack detection; (l) die assembly; (m) stamping parts.

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