​ ​Seminar on Design and Fabrication Methodologies of Forming Dies with the Improved Functionality Using Metal Additive Manufacturing Processes

 Chosun University, Korea

Since a metal additive manufacturing (AM) process has been developed, forming dies were regarded as one of promising applications of the metal AM process due to their order adaptive characteristics. However, lead-time and cost of significantly are increased as compared to conventional manufacturing process of forming dies when a whole structure of forming dies is fabricated from the metal AM process. In addition, the metal AM process has several inherent demerits, including rough surface, brittle property, difficulty to create a fine detail, etc., to apply the process to manufacture of forming dies. Due to these disadvantageous characteristics of the metal AM process, the metal AM process has been only adopted to fabricate prototype forming dies for evaluation of shape and operation of the designed dies. The concept of a hybrid metal AM technology and a functional decomposition presents a new way to apply the metal AM process to manufacture of forming dies. In addition, layer-by-layer deposition characteristics of AM process can easily assign the desired functionality to a specific region. The aim of the paper is to investigate design and fabrication methodologies of forming dies with the improved functionality using a metal AM process. The design methodology of forming dies, including a computer aided engineering (CAE) and design for manufacturing (DFM), is proposed to enhance functionality of forming dies and manufacturing efficiency of fabricated dies. In addition, the fabrication methodology, including substrate manufacturing, multi-layers deposition and post-processing, is suggested. Through several case studies, the applicability and the benefit of the proposed design and fabrication methodologies are discussed.

Prof. Dong-Gyu Ahn received his B.S. degree in Dept. of Production & Mechanical Engineering from Pusan National University, Korea, in 1992. He then received his M.S. and Ph.D. degrees from KAIST in 1994 and 2002, respectively. He is currently a professor at the Department of Mechanical Engineering, Chosun University in Gwang-Ju, Korea. Also, he is in charge of senior editor of IJPEM-GT (International Journal of Precision Engineering and Manufacturing-Green Technology), editorial board of IJPEM, editor of JKSPE, vice editor of Transactions of KSME, chairman of additive manufacturing division of KSPE (Korean Society of Precision Engineering), chairman of 3D Printing Users’ Forum, and former chairman of manufacturing and design division of KSME (Korean Society of Mechanical Engineers). Prof. Ahn’s research interests include development & application of 3D printing process, rapid manufacturing, lightweight sandwich plate, molds & die, and finite element analysis.