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Application Cases and Integration of Additive Manufacturing Processes into Conventional Process Chains by the Example of Tool Repair Using the Con-trolled Metal Build-Up Process
KTH, School of Industrial Engineering and Management (ITM), Production Engineering.
2015 (English)Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

In the first part of this thesis an overview of the most common Additive Manufacturing (AM) processes and a valid classification scheme outside of the classification of conventional ma-chining processes is presented. Advantages and shortcomings of these processes are briefly explained and application cases from the industry are given. Transitioning from the shortcom-ings of current Additive Manufacturing processes the so called “hybrid additive subtractive” processes are introduced.The concept, setup, and machinery of these systems are explained by the example of the Controlled Metal Build-Up (CMB) process, a hybrid additive-subtractive process developed at the Fraunhofer IPT in Aachen, Germany. Competitors as well as potential application cases are exhibited. Based on the identified lack of feasible process chains for Additive Manufactur-ing, an improved alternative process chain for the usage of the CMB process is then introduced taking automation and a broad applicability into account.In an additional part exemplary material properties of a component created with CMB are ex-amined. Based on the results of a previously created tool that was manufactured by CMB and which displays a significantly increased service time, tribological tests are conducted for differ-ent test specimens as well as for reference parts.The experiments serve to increase the applicability of the CMB process to other components and to improve the deposition strategy and material properties of the manufactured parts and thus to validate the developed process chain. The experimental design as well as the obtain-ment of results are explained in detail.It is shown, that the angularity between the line of force during the testing and the weld seam deposition direction has a significant influence on the wear behavior of the deposited material. Based on the findings it is recommended to design the deposition process in such way that the deposited weld seams are in line with the direction of force during operation.Furthermore it is shown that the chosen tribological tests only have a limited validity and cannot be transferred to the real application case, since the results of the significantly increased life time of the tool could not be reproduced. During the tests the deposited weld seam surface is not generally superior to a hardened surface, as it was previously assumed. One reason might be a failure during the hardening of the test specimens and thus undesired material properties that prevent comparability of the obtained results. The shortcomings and problems are dis-cussed and an outlook on further studies and applications for CMB is given.

Place, publisher, year, edition, pages
2015. , 105 p.
, Degree Project in Production Engineering Management, Second Level, 663
National Category
Engineering and Technology
URN: urn:nbn:se:kth:diva-183095OAI: diva2:907572
Available from: 2016-02-29 Created: 2016-02-29 Last updated: 2016-02-29Bibliographically approved

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