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: kristian.arntz@ipt.fraunhofer.de WZL/Fraunhofer IPTSeite 43