3D프린팅 금형을 이용한 알루미늄 판재 성형 공정과 마찰 변형 연구

Abstract

This study investigated the feasibility of using 3D-printed dies for metal-sheet forming processes, focusing on the performance of dies produced using fused filament fabrication. A punch and die set for the 90° V-bending of a 2-mm-thick Al6061 sheet were fabricated using PLA, ABS, and PA6-CF filaments. The mechanical performance and dimensional accuracy of the formed aluminum parts were evaluated, particularly in terms of bending angle and radius. Results revealed that both the mechanical properties of the 3D-printed materials and design parameters, such as the build direction and infill density of the printed dies, significantly influenced the final bending characteristics. High contact pressure developed at the dies' shoulder during V-bending induced localized frictional deformation. Compared to PLA and ABS, PA6-CF exhibited the highest resistance to deformation, which is attributed to its enhanced mechanical strength. Furthermore, the direction of bead deposition during printing affected the frictional behavior and wear performance of the dies. The friction coefficient ranged from 0.06 to 0.16 depending on the material and orientation. However, no strong correlation between friction coefficient and frictional deformation was identified. These findings suggest that 3D-printed polymer-composite dies show considerable promise for light-duty metal forming applications. Nevertheless, further research is needed to enhance their durability and optimize material properties for broader industrial use.