Characterization and Finite Element Simulation of 3D printed Polymer Composite Tooling for Sheet Metal Forming

Speaker name: Madhura Athale, mechanical engineering student

Abstract:
Conventional sheet metal forming tooling in the automotive industry is made up of hardened steel and used for mass-production. Prototype tooling made of metal is durable, but it is only used for a small number of parts despite its high cost, contributing heavily to the vehicle development cost. Additive manufacturing (AM) offers a cost-effective and rapid tooling option for prototyping, and low cost, low volume sheet metal forming applications. Due to the high anisotropy in mechanical properties of 3D printed composites, accurate characterization, and finite element modeling of the material becomes paramount for successful design and application of these forming tools. This study investigates the feasibility of using AM polymer composite tooling for the stamping of HSS 590 steel sheets through a two-pronged approach – experimental and numerical analysis. It was found that the anisotropy and strain rate sensitivity of 3D printed polymer composites play a significant role in their performance as tooling materials. Fiber reinforced FDM and BAAM produced polymer composite tooling was found to be well suited for low volume production applications with potential cost savings. Finally, a multi-scale modeling methodology was developed to investigate the structure-property relationship and to capture the effect of porosity on the macroscopic anisotropy in elastic properties of FDM materials.

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Committee Members
Professor Farhang Pourboghrat
Professor Noriko Katsube
Professor Marcelo Dapino
Professor Jose Castro