Redevelopment of an Insert Holder for Additive Manufacturing
Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesis
Since more and more products are custom made the manufacturers are facing increasing demands requiring both time and cost efficiency. With conventional manufacturing methods it is often costly to produce custom made products in low volumes due to large initial onetime costs for machines, setup etcetera. Today it is possible to produce real, working products in metal materials with additive techniques such as laser sintering. Small grains of metal are melted or sintered together using a thin laser beam, creating precise geometries directly from a CAD-file.This thesis work was carried out at the CTSP department at Sandvik Coromant in Sandviken. The purpose is to show what kind of functional and design improvements can be achieved with the manufacturing technique as well as what limitations it implies. This is to be made by exemplifying a redevelopment of a Corocut insert holder for grooving operations. The aim is to successfully produce a functional insert holder conformal to the limitations of additive manufacturing. An analysis of the design process when designing for additive manufacturing should also be generated.The redeveloped insert holder had a decreased volume and a more slimmed design. Instead of a cooling channel with a diameter of 3 mm two channels with a diameter of 2 mm and 1 mm was added. The acute angles could be eliminated by using additive manufacturing, creating a better flow of the cutting fluid. The hinge was moved and more chip space could be generated.The insert holder was laser sintered in a machine from Concept laser. The additive process was made on top of a Capto coupling which had been sent to the manufacturer. Operations to create the insert seat and the clamping were made afterwards.Testes showed a well functional insert holder for grooving with a very gathered fluid jet from the 1mm cooling channel and good chip breaks.The manufacturing technique is applicable for Sandvik Coromant products, although the exact product areas need to be analysed. Examples of potential areas are for products with high demands on the cooling channels, spare parts, or areas where having different materials in the same geometry can be an advantage. The manufacturing technique is most suited for custom made (special) products, though the profit opportunities have not been analysed. Although, manufacturing products with additive techniques give a lot of freedom to the designers and make it possible to produce products that have not been possible before. Unique design and functions in a product may very well compensate for the higher price the customer has to pay.
Place, publisher, year, edition, pages
2011. , 103 p.
Teknik, Sandvik, additiv tillverkning, laser sintring, skärhållare
IdentifiersURN: urn:nbn:se:ltu:diva-44885Local ID: 2a1b4947-c8f5-4cad-925b-148b6cb214c9OAI: oai:DiVA.org:ltu-44885DiVA: diva2:1018164
Subject / course
Student thesis, at least 30 credits
Industrial Design Engineering, master's level
Validerat; 20110124 (anonymous)2016-10-042016-10-04Bibliographically approved