25-27 April 2022
Conventum Conference Center
Europe/Vienna timezone

Manufacturing of integrated cooling channels by directed energy deposition for hot stamping tools with ball burnished surfaces

26 Apr 2022, 16:10
Room 1

Room 1

Oral Presentation Additive manufacturing Additive Manufacturing


Ms Anna Komodromos (Institute of Forming Technology and Lightweight Components)


Hot stamping tools require cooling channels, preferably with a variety of sizes and a high positioning flexibility. Conventionally, these are machined. This represents a disadvantage because of the limited accessibility for milling tools and the low flexibility. By means of the Directed Energy Deposition (DED) process a flexible design of the cooling channels is possible. For this, conventional material is used as a base on which the tool part with the cooling channels is added by DED. Different geometries of cooling channels can be manufactured by DED in order to control the heat balance in the hot stamping tool during forming. In this context an agreement between the additive producibility and the surface fraction of the cooling channels, which contributes to the effective heat at the tool surface, is important. Experimental and numerical analyses demonstrate the possible configurations in this field. To reduce the surface roughness after the DED process, the tool surfaces are ball burnished subsequently. In this context, the influence of ball burnishing on the resulting roughness is investigated. Furthermore texturing of the surface can be applied for influencing the material flow in the hot stamping process. Bringing a defined pattern onto the tool surfaces (texturing) can be implemented by DED or ball burnishing – depending on the material properties of the metal powder. The effect of the surface integrity on the material flow is characterized by strip drawing tests in hot conditions. The combination of the described methods allows for manufacturing hot stamping tools with near-surface cooling channels and a global or local adjustment of the surface properties of the tools.

Speaker Country Germany

Primary author

Ms Anna Komodromos (Institute of Forming Technology and Lightweight Components)


Dr Rickmer Meya (Institute of Forming Technology and Lightweight Components) Mr Felix Kolpak (Institute of Forming Technology and Lightweight Components) Prof. A. Erman Tekkaya (Institute of Forming Technology and Lighweight Components)

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