- 1. Laser applications in tool and die making How light can
enable new product features Kristian Arntz Fraunhofer IPT, Aachen,
Germany International Seminar: Application of new technologies in
the metal mechanic sector Joinville, Brazil, September 2011
WZL/Fraunhofer IPT
2. Laser applications in tool and die makingPresentation outline
1 Using light for production Lasers as flexible production systems
2 Surface structures ablating material to generate design features
3 Wear resistance modifying material properties for better tool
lifetime 4 Generating parts Additive manufacturing for functional
moulds 5 High strength materials enhancing machining capability by
laser softening 6 Outlook how Lasers will contribute to future
process chains WZL/Fraunhofer IPT Seite 1 3. Laser applications in
tool and die makingWhat differentiates laser light from white
light?Properties of white light Properties of laser lightn
polychrome, light with different wavelengths /n monochrome, light
of a single wavelength / frequenciesfrequencyn Low coherence, short
wave trainsn High coherence, long wave trainsn High divergence,
broad diffusion, difficult to be n Low divergence, nearly straight
spreading, focussed and low intensity easy to be focussed and high
intensity Laser source LASERQUELLEm-areabis 1000 km WZL/Fraunhofer
IPT Seite 2 4. Laser applications in tool and die makingPrimary
process influencing factorsn Intensity distribution in working
plane Intensity is depending on time P(t)- Laser source and beam
parameters Intensity [W/cm] Intensity distribution depends on
geometryI(x, y, z)- Intensity distribution in primary beam (laser
source)- Beam caustics (result of optical system)- Location (and
orientation) of working plane y [mm]n Influencing time x [mm] Feed
rate (cw- and pw-mode) Pulse duration (and form), Pulse
frequencyz-(pw-mode)Focal planeWorking planez+cw: Continuous Wave
Modepw: Puls Wave Mode WZL/Fraunhofer IPTSeite 3 5. Laser
applications in tool and die makingBeam guidance and formation
Laser sourceBeam guidanceStrahlformung CollimationFocussing Focal
planeDirect emissionlenselenseExpansionRayleigh lengthlenseField
depthMirrorsFibre coupled Fibre optic(up to 100 m) WZL/Fraunhofer
IPTSeite 4 6. Laser applications in tool and die makingInfluence of
intensity and processing time on processcharacteristicsHeat
influence zoneMeltMetal steamEjectedmaterialIntensity 103 W/cm 105
W/cm 106 W/cm 108 W/cm 109 W/cm 1011 W/cmProcessing times - msms ms
- ss s - psps - fs n Heatingn Meltingn Melting n Evaporating n
Evaporating n SublimatingResult n Melting n Evaporating n
Sublimating n Hardeningn Hard brazing n Deep pene-n Drillingn
Engraving n Texturing tration welding n Soft brazing n Welding
Processes n Cuttingn Depositionwelding Any change in process and
system parameters influencing the intensity and ist distribution
results in a considerable change of process characteristics and
result! WZL/Fraunhofer IPT Seite 5 7. Laser applications in tool
and die makingExample laser hardening 1000100 1010,1[K/s]Principle
12001100n Absorption of laser light at partsLaser beam PL
1000surface AC1 1100n Heating up of near-suface areasMS homogene
austenite Temperatur1000 inhomogene austeniteto the temperature
of900austenitasation by heat Hardened area800 Ferrit + Perlit +
Austenitconduction (depth d 1 mm)vW700Ferrit + PerlitBulk
material600n Uench hardening by fast heatconduction into the inner
parts 0,1110 100 1000 10000[s]area (formation of martensite)ZTA
diagram Zeit 9001200C T [C] Austenite [%] Martensite [%]
800Advantages 700 F Ac1 600n High surface hardness with
fineAPTemperatur100% 500grained textureMS 400 Msn Local heat input
only300 B Mf 200n Low distortion 100 Heating Hold Coolingt [s] 760
533 200n Now chilling liquid 0,1110 100 1000 10000[s]ZTU diagram
time WZL/Fraunhofer IPTSeite 6 8. Laser applications in tool and
die makingPresentation outline 1 Using light for production Lasers
as flexible production systems 2 Surface structures ablating
material to generate design features 3 Wear resistance modifying
material properties for better tool lifetime 4 Generating parts
Additive manufacturing for functional moulds 5 High strength
materials enhancing machining capability by laser softening 6
Outlook how Lasers will contribute to future process chains
WZL/Fraunhofer IPT Seite 7 9. Laser beam structuring an innovative
process for surface structuringThe challenge of "surface
decoration" for tool and diemanufacturersEtchingn High manual
effortn Poor reproducibilityn Limited material range Eschmann
Texturesn Restricted flexibility related to the structure
designElectroformingn High manual effortn Moderate reproducibilityn
Poor flexibilityn No consistency of a (digital) data chain
Galvanoformn Limited material range A wider scope related to the
structure design, the increase of the reproducibility and the
reduction of the manual effort require innovative solutions for the
surface texturing in the tool and die manufacturing! WZL/Fraunhofer
IPTSeite 8 10. Laser beam structuring an innovative process for
surface structuringThe laser beam as a "tool" fast, flexible and
preciseSystem setup Pulsed laser source Laser scanner Dynamic beam
expanderTelecentricF-Theta lensWork pieceFraunhofer IPT
WZL/Fraunhofer IPT Seite 9 11. Laser beam structuring an innovative
process for surface structuring"Removal rate and surface quality"
process basics n Use of pulsed laser sources Pico- and nanosecond
laser n Ablation with ps-laser (1 picosecond = 10-12 sec) Material
removal by sublimation (multi-photon-absorption):"Cold" ablation
process => no thermal conduction Nearly all materials are
processableFraunhofer IPT Removal of a small material volume by a
single laser pulse No melt formation on the surface n Ablation with
ns-laser (1 nanosecond = 10-9 sec) Linear absorption Predominantly
melt ablation:Thermal process with melt formation Limited range of
processable materials Removal of a large material volume by single
laser pulse Low-cost laser sources WZL/Fraunhofer IPT Seite 10 12.
Laser beam structuring an innovative process for surface
structuring"Complex shaped surfaces" machine tools and CAM-system
Work 3D-model pieceFraunhofer IPTn Machining centers n Completely
CAM-based tool path planning and Modified 5-axis- precision-machine
tools process parameter selectionn 4 additional axes by beam
guidance system n Simulation, analysis und optimization of tool
paths(x, y, z and c-axis)n Advantagesn Integrated laser sources
Modular setup guarantees the transferability to industrial
Picosecond laser (LUMERA Laser)used CAM systems Nanosecond laser
(EdgeWave) Simulation of the machine kinematics for collisionn
Heidenhain 530i - controlmonitoring between work piece and machine
WZL/Fraunhofer IPT Seite 11 13. Laser beam structuring an
innovative process for surface structuringApplication example "free
formed surface tulip designWork piece specificationn Demonstrator
with an arched surfacen Basis material 1.2343 (X38CrMoV5-1)n
Quenched and tempered to 50 +2 HRCResultn Large-scale and seamless
surfaceFraunhofer IPTstructuringn Laser structured area: 80 mm x 60
mmn Maximum depth of structure: 150 mFraunhofer IPT WZL/Fraunhofer
IPT Seite 12 14. Laser beam structuring an innovative process for
surface structuringApplication example "injection mold" free formed
surfaceWork piece specificationn Injection moldn Basis material
1.2343 (X38CrMoV5-1)n Quenched and tempered to 50 +2 HRCn Laser
structured area: Fraunhofer IPT 196 mm x 152 mmResultn Large-scale
and seamless surfaceFraunhofer IPTstructuring Leather-grain K3A of
the Volkswagen GolfVI Fraunhofer IPT Hybrid-structure with micro-
and macrostructures Geometrically defined pyramid
structuresFraunhofer IPT WZL/Fraunhofer IPT Seite 13 15. Laser beam
structuring an innovative process for surface
structuringApplication example "injection mold" airbag shock
absorbing pad Work piece specification n Injection mold for the
sample production of an airbag shock absorbing pad (VW Golf VI) n
Basis material 1.2311 (40CrMnMo7) n 240 mm x 130 mm x 240
mmFraunhofer IPT Result n Laser structured area with a diameter of
175 mm n Large-scale and seamless surface structuring with a smooth
structure transition Leather-grain K3A of the Volkswagen Golf
VIFraunhofer IPT Design-triangle structure WZL/Fraunhofer IPTSeite
14 16. Laser beam structuring an innovative process for surface
structuringApplication example mould ring" Tool deairingn Base
material 1.2379 (X153CrMoV12)n Part diameter: 55 mmn Micro
structure was modeled in CADn Depth gradient of micro structure: 10
m to 200 mn Applied laser system enables melt and burr free
manufacturingFraunhofer IPT WZL/Fraunhofer IPT Seite 15 17. Laser
applications in tool and die makingPresentation outline 1 Using
light for production Lasers as flexible production systems 2
Surface structures ablating material to generate design features 3
Wear resistance modifying material properties for better tool
lifetime 4 Generating parts Additive manufacturing for functional
moulds 5 High strength materials enhancing machining capability by
laser softening 6 Outlook how Lasers will contribute to future
process chains WZL/Fraunhofer IPT Seite 16 18. Local wear
resistance Laser as a flexible production toolOne Tool a variety of
customized possibilities n Laser hardening Process principle Laser
Powder Gas n Laser cladding Laser beamWork pieceTreated zone n
Laser alloyingLaser feed Feed raterate n Laser dispersing
WZL/Fraunhofer IPTSeite 17 19. Local wear resistance Laser as a
flexible production tool Material and surface variety: Process
basicsn Fibre-coupled diode laser system Laserline LDF 400-5000
Power output 5000 W Variable focusing of laser spot diameter from
0.8 to 3 mmn Additive material Alloying/dispersing: WC-Co-Cr, VC,
TiC as powder material Cladding: Stellite, similar material (powder
or wire)1000 HV 0,1 Powder feeding is proceeded by a co-axial
nozzle (optional also sideways)800 Wire-feeding is proceeded using
a sideward feeding system60042 HRC400 45 HRC53 HRCn Process gas56
HRC200 Argon0,1 0,50,9 1,3 1,7 2,12,5 Dist ance f rom surf ace [mm]
Supplied with the additive material WZL/Fraunhofer IPTSeite 18 20.
Local wear resistance Laser as a flexible production toolChallenge:
Wear resistance within tool making Forging dies for hot tooling n
Local crack formation due to variations in temperature n Abrasive
wear at edges Die casting moulds n Local fire crack formation n
Abrasive wear at edges, bars and within the inlet areaDies and
punshes for cold formingn Fatigue fractures starting at surfacen
Abrasiver wear Injection moulds n Abrasive wear at edges and
junctions n Importance of keeping the surface quality and geometry
Need for local enhancement of material properties and surface
quality for complex geometries in individual or small series
production within tool making! WZL/Fraunhofer IPTSeite 19 21. Local
wear resistance Laser as a flexible production toolComplex
geometries: Machining system and CAM-systemn Integration of all
components in a precise fixe n Complete CAM-integrated machining
pathaxis machining system planning and process parameterizationn
Robust, enclosed machining system including n Simulation, analysis
and optimization ofsuction machining path and coatingn Using of all
control functionalities andn Modularity ensures a transferability
tointegration of laser features by interpolationcustomary
CAM-systemsclockn Simulation of machine kinematic forcollision
monitoring of part and machine WZL/Fraunhofer IPT Seite 20 22.
Local wear resistance Laser as a flexible production
toolCAx-Framework Graphical User Interface (GUI) Technologyn
Graphical User Interface (GUI)Active Domain classes parameter
Graphicfor all processing stepsinputn Process-specific strategy
optionsn Intuitive guidance through menun User-defined parameter
input Geometry, Strategy, Tool, Process etc.n Active Graphics for
ad-hoc visualizationof active input parametern Input status is
signalized by set of trafficlightsn Direct feedback and help texts
for the usern Bilingual implementation (German/English) Status ofn
Simplified and expert modeParameter Parametersparameterdescription
input WZL/Fraunhofer IPTSeite 21 23. Local wear resistance Laser as
a flexible production toolAutomated laser surface treatment
Machining system Alzmetalln TargetMachining system for 5-axes laser
surface treatment ofparts to enhance the wear resistancen Used
processes Laser hardening, Laser remelting Laser alloying, Laser
dispersing Laser claddingn Technical specifications Gantry-Concept
(5-Axes simultaneous) Traverse path X-,Y-Axis: 800 mm; Z-Axis: 600
mm Position accuracy 0.007 mmn Rotary/ Tilting unit A-Axis tilting
range 140 C-Axis turning range 360 (continuously) Turning table
diameter 320 mmn Fibre coupled diode laser systemn NC-Control
Siemens SINUMERIK 840 D Solution Line WZL/Fraunhofer IPT Seite 22
24. Local wear resistance Laser as a flexible production tool5-axis
laser surface treatment Movie of the process WZL/Fraunhofer
IPTSeite 23 25. Local wear resistance Laser as a flexible
production toolExample of laser dispersing: Forging die
PedalSpecifications of the dien Treatment of upper and lower dien
Base material 1.2344 (X40CrMoV5-1)n 400 x 140 x 100mmn
Conventional:Gas nitriding (thickness: 0.2 mm)n Innovative process
chain:Forged part Laser surface treatment Laser dispersing and
nitridingResultn Conventional:Lifetime 6000 partsn Laser surface
treated:Lifetime 10800 respectively 11000 partsLaser dispersed area
of the Increase in lifetime of about 80%Use in applicationdie
WZL/Fraunhofer IPTSeite 24 26. Local wear resistance Laser as a
flexible production toolExample of laser alloying: Aluminum die
casting toolSpecifications of the dien Treatment of Aluminum die
casing insertsn Base material 1.2343 (X38CrMoV5-1)n Max.
dimensions: 55 mmn Conventional: gas nitridingSurface which has to
be n Innovative process chain:treated Laser alloying and
nitridingResultn Conventional:Lifetime 5 000 partsn Laser surface
treated:Lifetime circa 10 000 partsEmbedded insert of an Increase
in lifetime of about 100%Laser surface treatmentAluminum die
casting tool WZL/Fraunhofer IPT Seite 25 27. Laser applications in
tool and die makingPresentation outline 1 Using light for
production Lasers as flexible production systems 2 Surface
structures ablating material to generate design features 3 Wear
resistance modifying material properties for better tool lifetime 4
Generating parts Additive manufacturing for functional moulds 5
High strength materials enhancing machining capability by laser
softening 6 Outlook how Lasers will contribute to future process
chains WZL/Fraunhofer IPT Seite 26 28. Generating parts Additive
manufacturing for functional mouldsIntegrated deposition welding
and milling n Wire based technology n Layer-by-layer generation of
metallic parts in a combination of wire deposition welding and HSC
milling n Integration of combined process into one machinning
system n Post machining of every (n) layer offers the possibility
to utilise small milling tools and though highly precise machining
n Technology can be transferred to specific needs in terms of
machining system and parts which have to be manufactured
WZL/Fraunhofer IPTSeite 27 29. Generating parts Additive
manufacturing for functional mouldsTool repairInitial situationn
Mould defectTargetn New build up of defect aresSolutionn Failure
identificationn Design of welding and milling area10 mmn Generation
of NC dataPre-milling and deposition welding Pre-machiningn
Pre-machining by millingn Laser wire deposition weldingn Post
machining of contourAprroximated time framen Programming: ca. 2,5
hn Manufacturing time: < 45 min WZL/Fraunhofer IPTSeite 28 30.
Generating parts Additive manufacturing for functional mouldsTool
modificationInitial situationn Design changeTargetn Partly
automated geometry changeSolutionn Design of welding and milling
arean Generation of NC data Application oif change Pre-machining of
milling arean Pre-machining by millingn Laser wire deposition
weldingn Post machining of contourAprroximated time framen
Programming: ca. 60 minn Manufacturing time: ca. 30 min Applied
welding geometry Finished part WZL/Fraunhofer IPTSeite 29 31.
Generating parts Additive manufacturing for functional mouldsTool
build for filigree geometriesInitial situationn Mould insert for
injection mouldingn Base 50x50 mmTargetn Build up of
geometrySolutionn Splitting in base and build area10 mmn Generation
of NC data Splitting in base and build area Splitting in base and
build arean Pre-machining by millingn Laser wire deposition
weldingn Intermittent contour milling and final post machining of
contourAprroximated time framen Appr. 2 days for each partFinished
partFinished part WZL/Fraunhofer IPTSeite 30 32. Generating parts
Additive manufacturing for functional mouldsAdditive Manufacturing
of a Mock-up Compressor
BladeCAM-ModuleCAM-ModuleCAM-ModuleLaser-additive Laser-additive
manufacture Optical measurement Digitized model Adaptive
millingmanufacturedof compressor blade of compressor blade of the
built-up bladefor contouringbladeCAx-FrameworkSimulation
SimulationSimulation Module ModuleModuleSimulation ofSimulation
ofSimulation of laser scanninglaser cladding re-contouringprocess
processprocess Source: Fraunhofer ILTSimulationSimulation
SimulationScreenshotScreenshot ScreenshotLaser-additive
manufactureLaser ScanningAdaptive millingSource: Fraunhofer IPT,
Fraunhofer ILT 2011 WZL/Fraunhofer IPTSeite 31 33. Generating parts
Additive manufacturing for functional mouldsCAx Solutions for
Digital MeasurementsCAM Solutions for Inline Metrologyn CAM module
for inline metrology Toolpath planning for geometry acquisition
using laser stripe sensors For Coordinate Measurement Machine
(CMM), robot or machine tool integrated sensor Sensor calibration
using adequate strategies 3-axis, 3+2-axis, 5-axis Transformation
and analysis of acquired geometry data Specialized analysis
functionalities e.g. for turbine blades Direct availability of
acquired data in CAD/CAM system for subsequent processes
Parameterized internal sensor model to support a wide range of
sensorsn Machine tool integrated laser stripe sensor overcomes
disadvantages of measurements on CMM High data rate No transport
time Decreased set-up time 5-axis measurements for best orientation
of sensor to surface Single reference for measuring and machining
no need to apply fittingfunctionsSource: Fraunhofer IPT /
CAx-Technologies, Production Metrology 2011 WZL/Fraunhofer IPT
Seite 32 34. Generating parts Additive manufacturing for functional
mouldsMachine and Process SimulationMachine Simulationn Simulation
of: Laser scanner path Milling machine Laser machine Coordinate
Measuring Machine - CMMSimulation of machine toolintegrated scan
systemn Simulation of CNC toolpath for cavity geometry for: Laser
scanning Rough and finish milling Milling to re-contour Laser
cladding Simulation of millingn BenefitsSimulation of laser systems
processes Decision making on choice of handling systems Simulation
of toolpath for verification Simulation of machine kinematics for
collision detection of part and machineIntegration of material
Material removal and tool-material-engagementremoval and cutter
conditionsengagement simulation Source: Fraunhofer IPT /
CAx-Technologies 2011 WZL/Fraunhofer IPT Seite 33 35. Laser
applications in tool and die makingPresentation outline 1 Using
light for production Lasers as flexible production systems 2
Surface structures ablating material to generate design features 3
Wear resistance modifying material properties for better tool
lifetime 4 Generating parts Additive manufacturing for functional
moulds 5 High strength materials enhancing machining capability by
laser softening 6 Outlook how Lasers will contribute to future
process chains WZL/Fraunhofer IPT Seite 34 36. Laser-assisted
cuttingTechnical ceramics Fields of application Main fields of
application for technical ceramics Mechanical engineering Chemistry
and process engineering n Nozzlesn Fillers n Rolling elements n
Liners n Extrudersn Tubes n Ringsn n Roller bearings PumpsMotors /
Turbines n Bushings n Bushings n Plungers n Plungers n Sealings n
Valves n bush bearingsn Roller bearings n cylinders, n Turbine
wheels Textile machineryMedical equipment n Guiding elements n
Globes n Spinning elementsn Globe seats n Knifes n articular n
Nozzlescomponentsn WZL/Fraunhofer IPTSeite 35 37. Laser-assisted
cuttingTechnical ceramics Application examples Application Examples
(by industry sector) 1 Drawing, cold forging Non ferrous metal
forming 2 mMicrostructure of a silicon nitride ceramic Metal
forming Mechanical engineeringProperties of Si3N4 high strength and
toughness high wear resistance good chemical resistance excellent
thermal fatigue resistance low heat expansion WZL/Fraunhofer
IPTSeite 36 38. Laser-assisted cuttingMachining of high-strength
materialsProcess characteristicn Improved machinability of
high-strength materials like titanium-, nickel- and cobalt-based
alloys as well as silicon nitride ceramics by localized heating of
the cutting zoneAdvantagesn Efficient cutting of materials that are
difficult to machine significantly higher cutting volumes and
longer tool life timesn Considerably shorter manufacturing times
and lower costsn Elimination of cooling lubricants (dry machining)n
Geometrically flexible, economic manufacture of complex components
made from technical ceramics (silicon nitride ceramics)n Highly
reproducible manufacturing quality due to very good control of the
laser sourceSource: A. Monforts Werkzeugmaschinen GmbH & Co. KG
(picture 1) WZL/Fraunhofer IPT Seite 37 39. Laser-assisted
cuttingTool turret with integrated laser beam guidance n
Flexibility: Any combinations of Laser-assisted cutting
Conventional cutting Laser surface treatment (Hardening, ) n
Modularity n Easy to handle Handling of optical tools without
laser-specific skills possible Extremely short tool exchange and
set-up times Laser integration does not restrict the original
functionality ofthe machine tool n Robustness Wear-resistant
Low-maintenance n Retrofitting Easy retrofitting in conventional
turning lathes possible WZL/Fraunhofer IPTSeite 38 40.
Laser-assisted cuttingMachine tool with integrated laser beam
guidanceTechnical specificationsn 2-axes CNC-turning lathen Main-
and opposed spindlen Wear- and maintenance-freehydrostatic guidance
ofZ-axisn Travel increments as low as0,001 mm without
stick-slip-effectsn High stiffness and gooddampingn True running
accuracy ofspindle: 0,003 mmn Max. swing diameter overcross slide:
280 mmn Max. turning length: 600 mmn Fibre-coupled diode
lasersystemSource: A. Monforts Werkzeugmaschinen GmbH & Co. KG
WZL/Fraunhofer IPTSeite 39 41. Laser applications in tool and die
makingPresentation outline 1 Using light for production Lasers as
flexible production systems 2 Surface structures ablating material
to generate design features 3 Wear resistance modifying material
properties for better tool lifetime 4 Generating parts Additive
manufacturing for functional moulds 5 High strength materials
enhancing machining capability by laser softening 6 Outlook how
Lasers will contribute to future process chains WZL/Fraunhofer IPT
Seite 40 42. Laser applications in tool and die makingOutlook and
vision Lasers in tool and die manufacturing can contribute to n
reduced processing time by developing intelligent machining
andprocessing strategies n New functionalities by realising adapted
and highly sophisticatedsurface properties n increased quality by
realising local wear protection The integration of laser systems in
machine tools contributes to n the design of continous process
chains including preliminarywork and finishing n Specific setting
of local material properties by automaticallycombining different
manufacturing processes n New functionalisation concepts by using
reasonable toolmaterials combined with surface modifications
WZL/Fraunhofer IPTSeite 41 43. Laser applications in tool and die
makingPresentation outline 1 Using light for production Lasers as
flexible production systems 2 Surface structures ablating material
to generate design features 3 Wear resistance modifying material
properties for better tool lifetime 4 Generating parts Additive
manufacturing for functional moulds 5 High strength materials
enhancing machining capability by laser softening 6 Outlook how
Lasers will contribute to future process chains WZL/Fraunhofer IPT
Seite 42 44. Your contact to Fraunhofer IPT Dipl.-Ing. Kristian
Arntz Head of department Laser Materials Processing Fraunhofer
Institute for Production Technology IPT Steinbachstrae 17, 52074
Aachen Phone: +49 241 89 04-121 Mobile:+49 174 1902817 Fax:+49 241
89 04-6121 Mail: [email protected] WZL/Fraunhofer
IPTSeite 43