As technology advances, there is an increasing demand for large cutting tools in cutting tools such as the aerospace and automotive industries. However, larger cutting tools mean more weight, which can lead to spindle damage, tools falling off the spindle, etc. 3D printing technology can help manufacturers solve that problems. 3D printing tool bodies not only bring larger cutters in line with weight requirements. but also ensure they outperform and outlast more conventional counterparts.
Titanium, aluminum, steel, and stainless steel tool bodies are manufactured using a selective laser melting (SLM) 3D printing system. Manufacturers can customize tools from complex and different materials according to product needs.
Most of the 3D printed tools are monoblock designs (tool holders are integrated into the tool body to increase rigidity) for reaming, circular interpolation, milling, and face milling operations. These tools can become cumbersome and complex, with multiple shapes that allow for larger components to be machined; the addition of an internal honeycomb frame can reduce the weight of these tools by up to 30% without sacrificing torsional strength.
Benefits
In addition to producing cutting tools that meet the needs of the aerospace industry, the lightweight design offers several benefits. On the one hand, they protect the machine. On the other hand, lighter tools are less likely to fall off the spindle.
Tests of 3D printed face mills have also shown a 40% longer tool life compared to conventionally manufactured milling cutters. Because 3D printing allows companies to provide cutting tools with optimized coolant channels. Traditionally, coolant channels are drilled into cutting tools, which limits their design and therefore their effectiveness. 3D printed tools can contain channels for more efficient delivery of coolant to the cutting edge. Better coolant flow can increase metal removal rates by up to 30% and help users implement MQL (Minimum Quantity Lubrication).
Due to the precision of the 3D printing process and the possibility of adding passive silencers. Thus, the balance of the 3D printed tool has also been improved, further increasing the life of the tool.
Additive manufacturing has been seeing widespread application in various aspects of engineering like Aerospace, Automotive, Medical, Consumer Electronics, Robotics, and many more. Without the constraints of traditional manufacturing techniques, AM has been encouraging the industry to design, develop, and produce parts of higher complexity.
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