Use of additively manufactured forging dies with contour-adapted internal cooling

The main aim of the research project is to increase the tool life by introducing contour-adapted internal cooling channels into forging dies. Due to the difficulty of realizing internal structures using machining processes, these are produced using additive manufacturing processes (selective laser melting). The tool material used is the practice-relevant hot-working tool steel 1.2365. Extensive series forging tests with in-process wear tests are carried out to evaluate the modified cooling concepts. With regard to tool wear, the thermal stress on the forging dies is particularly critical. Internal tool cooling can be expected to result in less softening of the hot-working tool steel due to more effective and permanent heat dissipation. This has a positive effect on the abrasive wear behavior and the plastic deformation of softened areas. The internal cooling channels can also be used for tool heating, which increases lubricant adhesion and reduces thermal shock stress. A lowered temperature control is developed for cooling and heating. Saving cooling lubricant shortens the cycle times during forming, which reduces production costs. Furthermore, a reduction in cooling lubricant has a positive effect on the environment, occupational safety and procurement costs. By combining conventional and internal cooling concepts, maximum cooling efficiency and increased tool life can be achieved. Companies from the hot forging and additive manufacturing sectors will benefit from the research project.