Additive manufacturing optimizes tools
Honeycomb structure makes bell mold lighter
Mapal has used the selective laser melting process to reduce the weight of its bell tool with brazed PCD cutting edges.
If the weight of PCD tools is reduced, it is usually possible to work with significantly higher cutting data. In addition to design freedom, the possibility of weight optimization is one of the key advantages offered by 3D printing. The weight can be significantly reduced thanks to specially developed structures inside the tool that cannot be produced conventionally.
One example of how Mapal uses this advantage of 3D printing in practice is the new bell tool with brazed PCD cutting edges. Bell tools are used, among other things, for the external machining of hose connections. These connections, for example on turbochargers, have to meet complex contour requirements. Production must be correspondingly precise. In order to produce economically and reliably in series, the company is also continuously working on improving existing processes.
Mapal has therefore optimized the existing, conventionally manufactured bell tool. The interior of the tool was modified using the selective laser melting process - instead of solid material, it now has a specially designed honeycomb structure. This makes the tool 30 percent lighter and the damping effect increases the tool life by around 40 percent. This allows faster machining, while the machining quality remains high.
Overall, the machining time has been reduced by 50 percent. In addition, the cooling channel guide has been optimized. The new bell tool is manufactured in a hybrid process. The new tool geometry is printed onto a high-precision base body with an HSK-63 interface using selective laser melting. The additively manufactured part is post-machined conventionally. The PCD cutting edges are then brazed on and shaped by laser.
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