Abstract

Low-volume prototype tooling is a large expense in vehicle development. Often, these tools cost a similar amount to mass-production tooling despite the much shorter useful life. Much of this cost is associated with the precision machining needed to create the tool geometry. Additive manufacturing brings with it the ability to create complex geometries at or near the final part shape. When applied to metal forming tools, additive manufacturing has the potential to reduce the cost and lead time of tooling by reducing the machining time required for traditionally manufactured tools. This study investigates the performance of sheet metal forming tools made from different polymer additive manufacturing materials and processes through forming trials on 1.6 mm thick 590 MPa high-strength steel, comparing the tools and their manufactured parts to traditional hard steel tooling and parts produced thereon. Physical die trials show success in forming mass-production materials accurately and tool life adequate to support low-volume production. A modeling framework has also been developed to rapidly iterate on new materials for tool design and application to other sheet metal grades and gauges.

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Author (organization or company)

• Ryan HAHNLEN（Honda Development and Manufacturing of America, LLC）
• Ben HOFFMAN（Honda Development and Manufacturing of America, LLC）
• Madhura ATHALE（The Ohio State University）
• Taejoon PARK（The Ohio State University）
• Farhang POURBOGHRAT（The Ohio State University）

Publication Information

Article of Honda R&D Technical Review Vol.36 (46 - 54)

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