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Technical Papers
homogeneous metal powder is selectively, i.e. at de ned positions, melted by a laser. In this way, the component is gradually built up. With the powder bed technique it is possible to produce components of complex and unprecedented structures, which would not be feasible by conventional processes.
In laser metal deposition, metallic powder or wire is fed via nozzles and melted by lasers at de ned spots. The unit that accommodates the laser and the nozzle may be actuated by a robot. Laser metal deposition achieves high build-up rates, but it is limited in terms of neness. For plastics-based components, the selective laser sintering (SLS) process is available. This technique is very similar to the powder bed process using metals, the only basic difference being that it uses a special powder of plastics material melted by a laser.
New way of thinking required
Robert Banse, member of the AM R&D Project Team of SMS group: “We adopt an entirely new approach to component designing. We are in no way restricted by any manufacturing constraints. We do not have to consider the geometry of the input stock, e.g. a forging blank, or the speci c requirements posed by machining processes such as milling or drilling. Therefore we can start out from the function the component is going to perform. We adopt a creative technological approach to designing. In other words: We develop the perfect shape for the func- tion at hand ready to be produced in the 3D powder bed printer. We have stopped thinking in terms of rectangular bores because in AM ow-optimized channels have become the most natural thing in the world.“
Innovative spray heads for forging plants
The advantages of Additive Manufacturing can be illustrated by way of the example of a spray head for cooling the dies in a forging press. Sarah Hornickel, who is also a member of the project team, explains: “The original spray head was a solid and heavy part. We redesigned the part in close cooperation with the responsible technical depart- ment and our simulation specialists. Additive Manufacturing allows us to design ow-optimized channels, do away with any super uous and heavy material and arrange the spray nozzles in such a way that the most intensive cooling takes place exactly where the highest temper- atures occur in the die. With the thus produced lighter-weight and individualized component, die cooling takes less time and becomes more ef cient – two aspects which will improve the productivity of our customers’ operations.”
Development within a strong network
Sarah Hornickel, Nina Uppenkamp and Robert Banse form the core AM team. They work with other supporters of AM and the various SMS group departments. Robert Banse: “I completed an apprenticeship and a dual study program at SMS group. During my studies, I specialized in Additive Manufacturing, a topic that fascinates me also outside my job. Within the SMS group community, we are very well networked and we have established a dedicated service network. These networks are just as important for the kick-off of new projects as technological know- how.“
Conventionally and additively manufactured roll cooling headers
ITAtube Journal No3/October 2019
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