Relatório de Boas Práticas de Fabricação Do Micromolde 1

Technology Guide for Mold 1
» Enhancement of the Technological Excellence of the

Brazilian Die and Mold Industry – Insight into Micro
Manufacturing Technologies «
This document presents three different process chains that were applied in order to
manufacture the micro structured parts of Mold 1. Information about machine tools,
process parameters and applied tools are given as well as measuring devices for
verification.
Contact Information:
Institute for Production Systems and Design Technology

Pascalstr 8-9
10587 Berlin, Germany
Brazil: David Carlos Domingos

Tel: +55 61 8347 7198
E-Mail: David.Carlos.Domingos@ipk.fraunhofer.de
Germany: Frederik Mahr

Tel: +49 30 39006 411
E-Mail: Frederik.Mahr@ipk.fraunhofer.de
Berlin, January 28, 2014

Technology Guide for Mold 1 Fraunhofer IPK
Contents
1. Introduction .................................................................................................................. 4
1.1. Objective and Tasks of the Project ........................................................................... 4
1.2. Overview about the Technology Guide .................................................................... 4
2. Process Chains and Course of Action ........................................................................... 5
2.1. Components of Mold 1........................................................................................... 6
2.2. Workpiece Preparation............................................................................................ 7
2.3. Measuring Strategies and Equipment ...................................................................... 8

2.3.1. Measuring Devices ..................................................................................................... 8
2.3.2. Characteristic Micro-Features for Workpiece Validation ............................................ 11
3. Process Chain 1.............................................................................................................14
3.1. Milling Machine Tool .............................................................................................14
3.2. Milling and Drilling Tools ........................................................................................15
3.3. Milling Strategies ...................................................................................................16

3.3.1. Manufacturing of Cavidade Fixa ............................................................................... 16
3.3.2. Manufacturing of Cavidade Movel ........................................................................... 18
3.3.3. Manufacturing of Mandíbula ................................................................................... 19
3.3.4. Manufacturing of EDM Electrodes for Process Chain 2 and 3 ................................... 21
3.4. Measurement Results Process Chain 1 ....................................................................23

3.4.1. Tactile Measurement Results – O-Inspect .................................................................. 23
3.4.2. Optical Measurement Results – Alicona InfiniteFocus................................................ 29
3.5. Tactile Roughness Measurements – Hommel Nanoscan ...........................................31
3.6. Summary of Process Chain 1 ..................................................................................31
4. Process Chain 2.............................................................................................................32
4.1. Wire-EDM Machine Tools .......................................................................................32
4.2. Wire Electrodes......................................................................................................33
4.3. Workpiece Clamping .............................................................................................35
4.4. Wire Electrical Discharge Machining (W-EDM) - Process Parameters .........................36

4.5. EDM Machine Tools – Die Sinking ..........................................................................41
4.6. EDM Tools .............................................................................................................42
4.7. EDM - Process Parameters ......................................................................................45
ii
4.8. Process Sequence ..................................................................................................48
4.9. Measurement Results - Process Chain 2 ..................................................................51

4.9.1. Tactile Measurements – Zeiss: O- Inspect .................................................................. 51
4.9.2. Optical Measurements - Alicona InfiniteFocus .......................................................... 56
4.9.3. Tactile Measurements - Hommel Nanoscan .............................................................. 57
5. Process Chain 3.............................................................................................................58
5.1. SLM Workflow.......................................................................................................58
5.2. Selective Laser Melting Machine Tool .....................................................................59
5.3. Selection of Powder Material ..................................................................................60
5.4. Analysis of the Powder Material 1.2709..................................................................61
5.5. Data Processing in CAE Environment ......................................................................64
5.6. Data Preparation in RP Environment .......................................................................72
5.7. SLM Build Process ..................................................................................................74
5.8. SLM Post-Processing ..............................................................................................74
5.9. Iteration Steps .......................................................................................................75
5.10. Mold Validation .....................................................................................................76
5.11. NC-Form Grinding and Milling Machine Tool ..........................................................80
5.12. Grinding Tools for the Machining of SLM Workpieces .............................................81
5.13. Machine Tool Setup and Referencing of SLM Workpieces........................................81
5.14. Challenges by machining of SLM workpieces ..........................................................83
5.15. Grinding Parameters ..............................................................................................85

5.16. CNC programs and strategy ...................................................................................88
5.17. Results of the Machining Processes within Process Chain 3......................................91
5.18. Comparison between Machining Strategies ............................................................95

5.19. Comparison between EDM Machining in 1.2709 (SLM) and Böhler M340 ...............96
6. Appendix A – List of Features .....................................................................................97
6.1. Cavidade Fixa (P11) ................................................................................................97

6.2. Cavidade Movel (P10) ............................................................................................99
6.3. Mandíbula (P14) ..................................................................................................102
iii
1. Introduction
1.1. Objective and Tasks of the Project

The overall objectives of this project are:
 to enhance the technological capabilities of SENAI and Brazilian Industry in the

production of micro-molds,
 to provide training to the experts from SENAI as well as to the industrial partners from
SENAI composing the Brazilian Network for Dies and Molds, regarding both
manufacturing technologies as well as measurement technologies in micro-production
engineering,
 to compare and optimize micro-machining technologies for producing micro-molds,

identify the limits of each technology and finally indicate the appropriate process chain
for a product and/or appropriate technology for a feature,
 to compare distinct measuring technologies for measuring micro molds, identify the
limits of each technology and present the solutions for each product and/or feature,
 to provide training to SENAI staff and to the industrial partners from SENAI composing
the Brazilian Network for Dies and Molds in the following Micro-manufacturing
Technologies: die-sinking EDM Machining, Selective Laser Melting, Micro-Milling as well
as Coordinate Precision Grinding,
 to provide training to SENAI staff and to the industrial partners from SENAI composing
the Brazilian Network for Dies and Molds in different Measurement Technologies, to
know: Precision Coordinate Measurement, Computer Tomography, Scanning Electron
Microscopy, Optical Measurement as well as Tactile Measurement for Surface
Characterization,
 to establish the National hub for improving the Brazilian die and mold industry through
know-how transfer and technological innovation.
1.2. Overview about the Technology Guide

In order to achieve the before mentioned objectives two different molds containing micro
structures shall be manufactured during the project. They were chosen at the Kick Off Meeting
in Joinville SC out of seven different product suggestions. Furthermore three different process
chains were defined to elucidate different ways of manufacturing as well as measurement.
The following technical guide contains the necessary information regarding the required
machine tools, measurement devices and other tools that are needed to manufacture the
workpieces required for the mold. Manufacturing examples, process parameters and
measurement results are presented as well as useful explanations that should help the
manufacturer in order to achieve comparable manufacturing results.
4
2. Process Chains and Course of Action
With the mold two different types of Dental Provisional Abutments shall be produced by
injection molding. Figure 2-1 shows the background of the product.
Figure 2-1: Purpose and schematic views of Dental Provisional Abutments
The mold design was initiated by the company FGM in Joinville, SC and handed to
Fraunhofer IPK by SENAI Joinville, SC. High Grade Stainless Steel: Böhler M340 Isoplast (54 HRC)
was chosen to be used as mold material. Three different Process Chains were defined during the
Kick Off Meeting to be realized during the project.
Micro Precision Injection

Process Chain 1 Molds Molds
Milling Grinding Molding
Micro Injection
Process Chain 2 Electrodes EDM Molds
Milling Molding
Precision
Grinding
Injection
Process Chain 3 SLM Molds Molds
Molding
Micro
Milling
Micro
Electrodes EDM
Milling
Figure 2-2: Process Chains used to manufacture the Mold 1
5
2.1. Components of Mold 1

According to Figure 2-3, Mold 1 is composed of seven parts. Only the cavities from part 1., 2.
and 3. contain micro structured features and will be discussed in this guide.
However all other parts such as the parts 4. and 5. (Macho Pilar), ejectors etc. were also
manufactured or obtained by furnishers of standard parts (e. g. HASCO) and handed to SENAI.
In order to guard against misunderstandings the Portuguese descriptions as well as the

numbering of the parts were used corresponding to the descriptions within the drawings and
the CAD data received from SENAI.
3. Mandíbula (P14)
1. Cavidade Fixa (P11)
2. Cavidade Movel (P10)
6. Bucha Extratora (22)
7. Bucha Extratora (23)
4. Macho Pilar Reto (P13)
5. Macho Pilar Angular (P12)
Figure 2-3: Components of Mold 1
6
2.2. Workpiece Preparation

The features of the components 4. to 7. (see Figure 2-3) are standard features and do not
necessarily need to be manufactured with micro machine tools and/or special high precision
equipment. Therefore they were pre-machined on standard machine tools (Milling, Drilling,
Grinding, Tapping). After the machining operations the workpieces were hardened through heat
treatment by induction hardening up to a workpiece hardness of 54 HRC as defined during the
Kick Off Meeting of the project.
Figure 2-4: Technical drawings for the pre-machining of the workpieces for Process Chain 1 and 2
During the heat treatment deformations occurred although an overmeasure of 0.1 mm on all
functional surfaces was defined. Unwanted shrinkage of the entire workpiece was the
consequence and the workpiece’s outer dimensions were too small. As a result of that the
alignment between Cavidade Fixa and Cavidade Movel made of hardened workpieces (Böhler
M340) did not fit. For future workpiece preparations an oversize of at least 0.25 mm should be
designated. However, in order to test the CNC paths for milling processes, test workpieces using
a softer tool steel (1.2343) at ~ 30 HRC were produced. They possess outer dimensions that met
the required tolerances. This tool steel should also be used during the optimization of the mold
functionality when modifications of the cavities, sprues and other important features are still to
be expected. Once the mold concept is entirely validated (including test injection processes), the
manufacturing should be carried out in hardened workpiece material (Böhler M340).
7
2.3. Measuring Strategies and Equipment

In order to measure and validate the manufactured parts tactile and optical measuring devices
were applied on characteristic and challenging features. In the following sections those features
are described as well as information about the technical data of the measuring devices are
given. However, the measurement results are displayed and described in the particular sections
of the three process chains.
2.3.1. Measuring Devices

Four different measuring devices were used for the validation of the produced parts. Figure 2-5
shows the Zeiss O-Inspect coordinate measuring device. It covered almost all dimensional
measuring tasks.
Figure 2-5: Coordinate measuring device Zeiss O-Inspect
Table 2-1: Technical data of Zeiss O- Inspect

specification
measurement principle optical zoom camera and tactile scanning tip

workspace 400 mm x 400 mm x 200 mm
measurement uncertainty 1.9 + L/250 μm
camera 2D with HD chip
objective lenses telecentric with 12x zoom
lighting circular LED (3D- features), coaxial imaging light,
transmitted light
8
In some cases optical measurements with a high resolution were necessary. Therefore an Alicona
InfiniteFocus System (Figure 2-6) was used. It enables very precise measurements and provides
3D data of the measured structures.
Figure 2-6: Optical measuring device: Alicona InfiniteFocus
Table 2-2: Technical data of Alicona InfiniteFocus

specification
measuring principle Autofocus-Variation (optical)
axis traveling distance 100 mm x 100 mm
max. workpiece height 100 mm
max. workpiece weight 20 kg
angles measurable up to 85°
measurement result 3D data (100 mio. picture elements)
resolution up to 10 nm vertical/400 nm lateral
Before the cavities could be measured on the Alicona Infinite Focus they were cut in sections
with the help of Wire- EDM. This allowed measurements of features which were not possible to
execute with the Zeiss O- Inspect.
Figure 2-7: Examples for inner workpiece structures
9
Although measurements for surface roughness are possible by optical focus variation, they are
not standardized. In that case a tactile device Hommel Nanoscan 855 was used (Figure 2-8).
Figure 2-8: Hommel Nanoscan 855 for roughness measurement
Table 2-3: Technical data of Jenoptik Hommel Nanoscan

specification
measurement principle tactile (contour and roughness)
traverse length 200 mm
measuring range 48 mm
resolution probe system 0.6 nm
measurement accuracy ± 0.5´ (angles), ± 0.01% (radius), ± 2 µm (distance)

roughness according to IN EN ISO 4288:1998
measurements
An optical measuring device using digital fringe projection was applied to analyze the
dimensional accuracy of the mold tools manufactured by the SLM Process. The accuracy of this
device is lower compared to the preceeding devices. However, the main goal was the
compensation of the material shrinkage factor and the deviations here are considerably higher
than the later workpiece tolerances. The visualization of the large scale 3D data enables the
analysis and optimization of SLM processes.
10
Optical measurement
Instrument:
 ATOS 3 400 SN
Test conditions:
 deviation 0.027 Pixel
 scale deviation 0.000 mm
 sphere spacing deviation 2 µm
 camera lense 40 mm
 camera angle 26.95°
 height variance 240.56 mm
Figure 2-9: Atos 3 400 SN digital fringe projection device for 3D shape measurements
2.3.2. Characteristic Micro-Features for Workpiece Validation
1. Feature 1.06.2: internal radii in the cavities (R = 1.879 mm)
2. Feature 1.06.3: angle (1.50°)
3. Feature 1.09.1: diameter of the H6 Fitting (1.50 mm)
4. Feature 1.06: position in x and y direction of the cavities
Figure 2-10: Characteristic features of Cavidade Fixa
11
1. Feature 2.06.1; 2.07.1: diameter at the entry of the cavity (D = 5.065 mm)
2. Feature 2.06.4; 2.07.4: angle of the cavity (30°)
3. Feature 2.06-3; 2.06.4: distance between vertical surfaces (4,25 mm)
4. Feature 2.09.1: diameter of the H6 Fitting (D = 3 mm)
5. Feature 2.06; 2.07: position in x and y direction of the cavities
Figure 2-11: Characteristic features of Cavidade Movel
12
1. Feature 3.01: angle 20°
2. Feature 3.02: radius 1.5 mm
3. Feature 3.07: angle 1.5°
4. Feature 3.09: diameter 1.5 mm
5. Feature 3.05: angle 10.32°
6. Feature 3.08: angle 63.61
7. Feature 3.03: distance 7.6 mm
8. Feature 3.04: distance 8 mm
Figure 2-12: Characteristic features of the Mandíbula
13
3. Process Chain 1
3.1. Milling Machine Tool

The applied machine tool for micro milling processes is displayed in Figure 3-1 and the technical
data are shown in Figure 3-2.
Figure 3-1: Machine Tool Primacon PFM 4024 5D
Figure 3-2: Technical Data from Primacon PFM 4024 5D
high Speed Spindle (HSK32E) 1,000 min-1 to 60,000 min-1 , 12 kW
fast Rotating C-Axis up to 2,500 min-1
max. Feed Rate vfmax = 40 m/min
Positioning Accuracy (VDI/DGQ 3441) of linear axes P ≤ 1.3 µm,

Ps ≤ 0.3 µm,
Pa ≤ 0.4 µm,
Umax ≤ 0.2 µm
Positioning Accuracy (VDI/DGQ 3441) of rotatory axes P ≤ 0.002°

Ps ≤ 0.0005°
14
3.2. Milling and Drilling Tools

For the cutting processes four different types of tools were used. In order to guarantee best
possible runout conditions, they were clamped using polygonal clamping chucks.
tool clamping end Mill cherry torus cutter drill

(ball end mill)
Figure 3-3: Tool clamping (Schunk) and different types of cutting tools (WNT and Mitsubishi)
Table 3-1 shows the technical specifications of the applied cutting tools. Tools from Mitsubishi
and WNT were used. The tools furnished by WNT are manufactured using cemented carbide
from Ceratizit. All tools are also available in Brazil.
Table 3-1: Technical Specifications of the applied milling tools

cutting number of coating shank length of
diameter teeth diameter cut
Project ID Product ID
[mm]
[mm] [mm]
end Mill WNT (Ceratizit) 12 2 - 12 50
(EM 12.0) 52639120
end Mill WNT (Ceratizit) 8 3 Ti20 8 20

(EM 8.0) 52639080

(EM 6.0) 52639060

(EM 5.0) 52639060
torus cutter WNT (Ceratizit) 6 4 Ti1000 6 16

(TC 6 x 0.5) 52108605
end mill Mitsubishi 3 6 TiAlN 6 10

(EM 3.0) VFMDD0300
drill WNT (Ceratizit) 3 2 Ti700 3 10
(D 3.0) 10739030
end mill Mitsubishi 2 4 TiAlN 6 7
(EM 2.0) VFMDD0200
cherry Mitsubishi 2 2 TiAlN 6 2
(C 2.0) VF299BR0200
torus cutter WNT (Ceratizit) 1.5 2 Ti2000 6 2,5
(TC 1.5 x 0.3) 52304015
15
3.3. Milling Strategies

For the CNC Programming Siemens NX8.0 was used in conjunction with a collision control of
the machine tool kinematic. The CNC Paths were controlled before actual milling on both
systems, the programming platform (Siemens NX8.0) and the machine tool control (Heidenhain
530i). Furthermore the actual tool diameters were measured beforehand and deviations were
compensated by the software.
3.3.1. Manufacturing of Cavidade Fixa

The features of Cavidade Fixa are shown in Section 6.1 of Appendix A. For the manufacturing of
Cavidade Fixa, six different cutting tools were used. Figure 3-4 shows schematic views of the
CNC paths.
The CNC operations as well as all relevant process parameters are displayed in Table 3-2. The
overall machining time was 94 min.
1. borehole 2. sprue (roughing)
3. sprue (finishing) 4. cavities (roughing)
5. cavities (finishing) 6. plane surface (finishing)
Figure 3-4: CNC paths of the milling operations for Cavidade Fixa
16
Table 3-2: CNC operations and process parameters of the milling operations for Cavidade Fixa
CNC operation tool spindle feed vf over- repetition total
speed n measure operation
[mm/min]
[1/min] time [min]
[mm]
1. borehole (drilling) D 3.0 1,200 12 - 2 1
2. sprue (roughing) C 2.0 40,000 250 1.4 4 13
3. sprue (finishing) C 2.0 40,000 700 0 (ap = 5% 4 4

DTool)
4. cavities (roughing) C 2.0 40,000 500 0.2 4 3
5. cavities (finishing) TC 1.5 19,000 165 0 4 33

x 0.3
6. plane surface (finishing) EM 3.0 16,000 1,500 0 1 25
17
3.3.2. Manufacturing of Cavidade Movel

The machined features of Cavidade Movel are shown in Section 6.2 of Appendix A. For the
manufacturing of Cavidade Movel, 7 different cutting tools were used. Figure 3-5 shows
schematic views of the CNC paths. In Table 3-3 the CNC operations as well as all relevant
process parameters are displayed. The overall machining time was 130 min.
1. borehole 2. sprue (roughing)
3. sprue (finishing) 4., 5. cavities (roughing)
6., 7. cavities (finishing)
8. ftting (finishing) 9. plane surface (finishing)
Figure 3-5: CNC paths of the milling operations for Cavidade Movel
18
Table 3-3: CNC operations and process parameters of the milling operations for Cavidade Movel
[mm/min]
[1/min] time [min]
[mm]
1. borehole (drilling) D 3.0 1,200 12 - 9 12
2. sprue (roughing) C 2.0 40,000 250 0.02 4 13
3. sprue (finishing) C 2.0 40,000 700 - 4 11
4. cavities (roughing) EM 2.0 24,000 500 0.05 4 2
5. cavities (roughing) EM 2.0 24,000 500 0.05 4 2
6. cavities (finishing) EM 2.0 24,000 400 - 4 1
7. cavities (finishing) TC 1.5 19,000 165 - 4 60

x 0.3
8. fitting (finishing) EM 2.0 24,000 300 - 4 4
6. plane surface (finishing) EM 3.0 16,000 1,500 - 1 25
For milling processes with identical types of tools, different tools were used for roughing and
finishing processes, e. g. processes 4., 5. for roughing and process 6. for finishing.
3.3.3. Manufacturing of Mandíbula

The machined features of Mandíbula are shown in Section 6.3 of Appendix A. For the
manufacturing of Mandíbula, six different milling tools were used. Figure 3-6 shows schematic
views of the CNC paths. In Table 3-4 the CNC operations as well as all relevant process
parameters are displayed. The overall machining time was 22 min.
19
1. plane surface (roughing) 2. sprue (roughing)
3. cavity (roughing) 4. sprue (finishing)
5. fitting (H6), 6. cavity (finishing) 7. plane surface (finishing)
Figure 3-6: CNC paths of the milling operations for Mandíbula

Table 3-4: CNC operations and process parameters of the milling operations for Mandíbula
CNC operation tool spindle feed vf overmeasure total operation
speed n time [min]
[mm/min] [mm]
[1/min]
1. plane surface (roughing) EM 3.0 16,000 1,500 0.1 3
2. sprue (roughing) EM 2.0 24,000 500 0.05 2
3. cavity (roughing) C 2.0 40,000 1,000 0.05 2
4. sprue (finishing) C 2.0 40,000 800 - 1
5. fitting (H6) TC 1.5 x 0.3 19,000 120 - 4
6. cavity (finishing) TC 1.5 x 0.3 19,000 160 - 8
7. plane surface (finishing) EM 3.0 16,000 1,500 - 2
20
3.3.4. Manufacturing of EDM Electrodes for Process Chain 2 and 3

For Process Chain 2 and 3 five different types of EDM electrodes were required. Copper (E-Cu
58) was chosen as electrode material. In order to enable roughing, finishing and polishing
processes three different sizes of the electrodes had to be manufactured. The undersize was
adjusted within the machine tool control. That means, the CNC programing had to be carried
out only once. The undersize of the electrodes were:
 roughing electrodes: undersize = 70 µm

 finishing electrodes: undersize = 20 µm
 polishing electrodes: undersize = 5 µm
The different EDM Electrodes are shown in Figure 3-7. The EDM Processes are explained in detail
in Section 4. All Electrodes needed for the manufacturing of Cavidade Fixa, Cavidade Movel and
the Mandíbula were arranged on one block. From this follows that all in all three blocks
(roughing, finishing and polishing electrodes) had to be manufactured. In Table 3-5 the CNC
operations as well as all relevant process parameters are displayed. The manufacturing time of
one block was 238 min. The overall machining time was therefore 3 x 238 min = 714 min
(~12h). After the milling processes the electrodes were cut off by W-EDM. Considering the
extremely long machining time which was mainly due to the time consuming roughing
processes, the application of a long automatic lathe (if available) is recommended for the
electrode manufacturing instead of a milling machine tool.
Figure 3-7: Applied tool electrodes and assembly block
21
Table 3-5: CNC Operations and process parameters of the milling operations for the EDM electrodes
[mm/min]
[1/min] time [min]
[mm]
1. roughing EM 12.0 1,326 266 0.1 1 60
2. roughing EM 8.0 7,958 1,194 0.1 1 45
3. roughing EM 6.0 10,610 955 0.1 1 12
4. semi finishing (tips) EM 6.0 7,958 1,194 0.05 30 8
5. finishing (tips) EM 5.0 9,549 1,146 - 30 2
6. cylinder 1 EM 5.0 6,379 383 - 8 2

(finishing)
7. Movel (finishing) TC 6.0x0.5 7,983 1,597 - 8 60
8. Mandíbula TC 6.0x0.5 7,983 1,597 - 4 18

(finishing)
9. Fixa (finishing) TC 6.0x0.5 7,983 1,597 - 4 27
10. cylinder 2 TC 6.0x0.5 7,983 1,597 - 6 4

(finishing)
22
3.4. Measurement Results Process Chain 1
3.4.1. Tactile Measurement Results – O-Inspect
Feature 1_01
Feature 1_02
Feature 1_03
Feature 1_04
Feature 1_08
Feature 1_06_01
Feature 1_06_02
Feature 1_06_03
Feature 1_06_04
Feature 1_06_05
Feature 1_09
Figure 3-8: Cavidade Fixa
23
Table 3-6: Cavidade Fixa (Böhler M340)
actual
designation/feature value nominal Tol. (-) Tol. (+) deviation error cause
1 length (x) 59.785 60.000 -0.018 -0.01 -0.2146 WP preparation
1 length (y) 59.785 60.000 -0.018 -0.01 -0.2150 WP preparation
1_01 height 5.004 5.000 -0.05 0.05 0.0038 -
1_08 diameter 1 7.997 8.000 0 0.009 -0.0034 EDM
1_08 diameter 2 8.001 8.000 0 0.009 0.0011 EDM
1_08 length 1 7.639 7.600 0 0.009 0.0385 EDM
1_08 length 2 7.679 7.600 0 0.009 0.0789 EDM
1_08 angle 1 20.2246 20.000 -0.3 0.3 0.2246 W-EDM
1_08 angle 2 20.6317 20.000 -0.3 0.3 0.6317 W-EDM
1_08 distance 1 14.3405 14.283 -0.02 0.02 0.0575 WP preparation
1_03 angle 9.9197 10.000 -0.3 0.3 -0.0803 -
1_03 angle 9.8114 10.000 -0.3 0.3 -0.1886 -
1_03 angle 9.9538 10.000 -0.3 0.3 -0.0462 -
1_03 angle 9.9902 10.000 -0.3 0.3 -0.0098 -
1_03 length (x) - 49.760 -0.02 0.02 - WP preparation
1_03 length (y) 50.9828 49.760 -0.02 0.02 1.2228 WP preparation
1_06_2 radius 1 1.8989 1.879 -0.02 0.02 0.0199 -
1_06_2 radius 2 1.8641 1.879 -0.02 0.02 -0.0149 -
1_06_3 angle 1 2.7055 1.500 -0.3 0.3 1.2055 tool wear
1_06_3 angle 2 2.1134 1.500 -0.3 0.3 0.6134 tool wear
1_09_1 diameter 1 1.5082 1.500 0 0.006 0.0082 tool wear
1_06 position 1 (x) 0.0039 0.000 -0.05 0.05 0.0039 -
1_06 position 2 (x) -0.0014 0.000 -0.05 0.05 -0.0014 -
1_06 position 1 (y) -150059 -15.000 -0.05 0.05 -0.0059 -
1_06 position 2 (y) 14.9926 15.000 -0.05 0.05 -0.0074 -
1_08 zero position 1 -0.0087 0.000 -0.05 0.05 -0.0087 -
1_08 zero position 2 0.0016 0.000 -0.05 0.05 0.0016 -
24
Feature 2_01
Feature 2_06
Feature 2_07
(lower cavity)
Feature 2_02
Feature 2_04
Feature 2_06_1
Feature 2_07_1
Feature 2_06_3
Feature 2_07_3
Feature 2_06_4
Feature 2_07_4
Feature 2_06_5
Feature 2_07_5
Figure 3-9: Cavidade Movel
25
Table 3-7: Cavidade Movel (1.2343 tool steel; ~30 HRC)

designation/feature actual value nominal tol. (-) tol. (+) deviation error cause
2 length (x) 60.0499 60.000 -0.029 -0.01 0.0499 CNC strategy
2 length (y) 60.0476 60.000 -0.029 -0.01 0.0476 “
2_07_1 diamater 1 5.0626 5.065 -0.05 0.05 -0.0024 -
2_06_1 diamater 1 5.0597 5.065 -0.05 0.05 -0.0053 -
2_07_1 diamater 2 5.0659 5.065 -0.05 0.05 0.0009 -
2_06_1 diamater 2 5.0564 5.065 -0.05 0.05 -0.0086 -
2_07_4 angle 1 29.9354 30.000 -0.3 0.3 -0.0646 -
2_06_4 angle 1 29.9078 30.000 -0.3 0.3 -0.0922 -
2_07_4 angle 2 30.0946 30.000 -0.3 0.3 0.0946 -
2_06_4 angle 2 29.7894 30.000 -0.3 0.3 -0.2106 -
2_07_3 distance 1 (x) 4.2465 4.250 -0.05 0.05 -0.0035 -
2_06_3 distance 1 (x) 4.1899 4.250 -0.05 0.05 -0.0601 Machine Tool
kinematic
2_07_3 distance 2 (x) 4.2536 4.250 -0.05 0.05 0.0036 -
2_06_3 distance 2 (x) 4.1862 4.250 -0.05 0.05 -0.0638 Machine Tool
kinematic
2_07_3 distance 1 (y) 4.2498 4.250 -0.05 0.05 -0.0002 -
2_06_3 distance 1 (y) 4.2075 4.250 -0.05 0.05 -0.0425 Machine Tool
kinematic
2_07_3 distance 2 (y) 4.2527 4.250 -0.05 0.05 0.0027 -
2_06_3 distance 2 (y) 4.1994 4.250 -0.05 0.05 -0.0506 Machine Tool
kinematic
2_09_1 diameter 1 2.9439 3.000 0 0.006 -0.0561 End Mill

compensation
2_09_1 diameter 2 2.9506 3.000 0 0.006 -0.0494 “
2_09_1 diameter 3 2.9766 3.000 0 0.006 -0.0234 “
2_09_5 diameter 4 2.9336 3.000 0 0.006 -0.0664 “
2_07 position 1 (x) -14.9981 -15.000 -0.05 0.05 0.0019 -
2_06 position 1 (x) 0.0087 0.000 -0.05 0.05 0.0087 -
2_07 position 2 (x) 15.0045 15.000 -0.05 0.05 0.0045 -
2_06 position 2 (x) -0.0028 0.000 -0.05 0.05 -0.0028 -
2_07 position 1 (y) 0.0028 0.000 -0.05 0.05 0.0028 -
2_06 position 1 (y) -14.9960 -15.000 -0.05 0.05 0.0040 -
2_07 position 2 (y) 0.0020 0.000 -0.05 0.05 0.0020 -
2_06 position 2 (y) 15.0064 15.000 -0.05 0.05 0.0064 -
2_03 length (x) -24.9658 -24.970 -0.05 0.05 0.0042 -
2_03 length (x) 24.9371 24.970 -0.05 0.05 -0.0329 -
2_03 length (y) 24.9681 24.970 -0.05 0.05 -0.0019 -
2_03 length (y) -24.9938 -24.970 -0.05 0.05 -0.0238 -
height 2_03 5.4983 5.500 -0.05 0.05 -0.0017 -
angle 2_03 10.1097 10.000 -0.3 0.3 0.1097 -
angle 2_03 10.0962 10.000 -0.3 0.3 0.0962 -
angle 2_03 10.1215 10.000 -0.3 0.3 0.1215 -
angle 2_03 10.1243 10.000 -0.3 0.3 0.1243 -
26
Table 3-8: Cavidade Movel (Böhler M340)
actual
designation/feature value nominal Tol. (-) Tol. (+) deviation error cause

2_07_1 diamater 1 5.117 5.065 -0.05 0.05 0.0523 end mill
compensation
2_06_1 diamater 1 5.100 5.065 -0.05 0.05 0.0351 “
2_07_1 diamater 2 5.119 5.065 -0.05 0.05 0.0539 „
2_06_1 diamater 2 5.100 5.065 -0.05 0.05 0.0353 „
2_07_4 angle 1 31.162 30.000 -0.3 0.3 1.1624 tool wear
2_06_4 angle 1 28.8385 30.000 -0.3 0.3 -1.1615 tool wear
2_07_4 angle 2 26.7458 30.000 -0.3 0.3 -3.2542 tool wear
2_06_4 angle 2 30.0348 30.000 -0.3 0.3 0.0348 -
2_07_3 distance 1 (x) 4.2508 4.250 -0.05 0.05 0.0008 -
2_06_3 distance 1 (x) 4.2000 4.250 -0.05 0.05 -0.0500 -
2_07_3 distance 2 (x) 4.2762 4.250 -0.05 0.05 0.0262 -
2_06_3 distance 2 (x) 4.2198 4.250 -0.05 0.05 -0.0302 .
2_07_3 distance 1 (y) 4.2645 4.250 -0.05 0.05 0.0145 -
2_06_3 distance 1 (y) 4.2141 4.250 -0.05 0.05 -0.0359 .
2_07_3 distance 2 (y) 4.2852 4.250 -0.05 0.05 0.0352 .
2_06_3 distance 2 (y) 4.2308 4.250 -0.05 0.05 -0.0192 .
2_09_1 diameter 1 3.0047 3.000 0 0.006 0.0047 -
2_09_1 diameter 2 3.0059 3.000 0 0.006 0.0059 -
2_09_1 diameter 3 3.0042 3.000 0 0.006 0.0042 -
-
2_07 position 1 (x) 15.0009 -15.000 -0.05 0.05 -0.0009 -
2_06 position 1 (x) 0.0086 0.000 -0.05 0.05 0.0086 -
2_07 position 2 (x) 14.9998 15.000 -0.05 0.05 -0.0002 -
2_06 position 2 (x) -0.0105 0.000 -0.05 0.05 -0.0105 -
2_07 position 1 (y) 0.0427 0.000 -0.05 0.05 0.0427 -
-
2_06 position 1 (y) 14.9544 -15.000 -0.05 0.05 0.0456 -
2_07 position 2 (y) 0.0434 0.000 -0.05 0.05 0.0434 -
2_06 position 2 (y) 15.0479 15.000 -0.05 0.05 0.0479 -
-
2_03 length (x) 24.9635 -24.970 -0.05 0.05 0.0065 -
2_03 length (x) 24.9669 24.970 -0.05 0.05 -0.0031 -
-
2_03 length (y) 24.9680 -24.970 -0.05 0.05 0.0020 -
2_03 length (y) 24.9400 24.970 -0.05 0.05 -0.0300 -
27
Feature 3_01
Feature 3_02
Feature 3_03
Feature 3_04
Feature 3_06
Feature 3_07
Feature 3_09
Table 3-9: Mandíbula 1(1.2210 tool steel; 54 HRC)
designation/feature actual value nominal tolerance (-) tolerance (+) deviation error cause
3_04 diameter 7.995 8.000 -0.009 -0.005 -0.0054 -
3_01 angle 20.012 20.000 -0.3 0.3 0.0119 -
3_02 radius 1.533 1.500 -0.05 0.05 0.0329 -
3_07 angle 2.257 1.500 -0.3 0.3 0.7570
3_09 diameter 1.503 1.500 0 0.006 0.0028
3_06 angle 10.195 10.320 -0.3 0.3 -0.1248 -
3_06 angle 61.525 63.610 -0.3 0.3 -2.0848
3_03 distance 7.5784 7.600 -0.009 -0.005 -0.0216
28
Table 3-10: Mandíbula 2(1.2210 tool steel; 54 HRC)
designation/feature actual value nominal Tol (-) Tol. (+) deviation error cause
3_04 diameter 7.994 8.000 -0.009 -0.005 -0.0057 -
3_01 angle 20.051 20.000 -0.3 0.3 0.0512 -
3_02 radius 1.560 1.500 -0.05 0.05 0.0595 tool wear
3_07 angle 3.148 1.500 -0.3 0.3 1.6483 tool wear
3_09 diameter 1.507 1.500 0 0.006 0.0073 tool wear
3_06 angle 10.388 10.320 -0.3 0.3 0.0676 -
3_06 angle 59.685 63.610 -0.3 0.3 -3.9254 tool wear
3_03 distance 7.5822 7.600 -0.009 -0.005 -0.0178 tool wear
3.4.2. Optical Measurement Results – Alicona InfiniteFocus
Figure 3-10: Cavidade Fixa Features
Table 3-11: Measurements Cavidade fixa
actual nominal upper tol. lower tol. deviation

Feature 1.06.1-1 4.935 mm 5.065 mm 0.02 mm -0.02 mm -0.130 mm
Feature 1.06.1-2 0.502 mm 0.507 mm 0.02 mm -0.02 mm -0.005 mm
Feature 1.06.2 1.8744 mm 1.879 mm 0.02 mm -0.02 mm 0.0046 mm
Feature 1.06.3 3.203 ° 3° 0.3 ° -0.3 ° 0.203 °
Feature 1.06.4 60.000 ° 60° 0.3 ° -0.3 ° 0.0000 °
29
Figure 3-11: Cavidade Movel Features
Table 3-12: Measurements Cavidade Movel

Feature 2.06.1 5.044 mm 5.07 mm 0.05 mm -0.05 mm -0.036 mm
Feature 2.06.4 29.856 ° 30 ° 0.3 ° -0.3 ° -0.144 °
Figure 3-12: Mandíbula Features

Table 3-13: Measurements Mandíbula
Mandíbula actual nominal upper tol. lower tol. deviation

Feature 3.01 19.943 ° 20 ° 0.3 ° -0.3 ° -0.057 °
Feature 3.02 1.465 mm 1.5 mm 0.05 mm -0.05 mm -0.034 mm
Feature 3.05 0.341 mm 0.343 mm 0.05 mm -0.05 mm -0.002 mm
Feature 3.07 3.196 ° 3° 0.3 ° -0.3 ° 0.196 °
Feature 3.08 59.58 ° 60 ° 0.3 ° -0.3 ° -0.42 °
30
3.5. Tactile Roughness Measurements – Hommel Nanoscan

Table 3-14: Surface Roughness Ra for Cavidade Fixa (Feature 1), Cavidade Movel (Feature 2) and
Mandíbula (Feature 3)
Ra [µm] nominal value

Feature measure 1 measure 2 [µm]
(longitudinal) (transversal)
Feature 2_06_01 0.076 0.091 < 0.2
Feature 2_06_04 1.918 - < 0.2
Feature 2_09_1 0.306 0.262 < 0.2
Feature 1_04 0.021 0.028 < 0.2

Feature 1_05 0.052 - < 0.2
Feature 1_06_03 0.132 0.111 < 0.2
Feature 3_06 0.456 0.242 < 0.2
3.6. Summary of Process Chain 1
 Optimized milling strategies (No. of Iterations = 4) led to a reduction of the overall

machining time from 8.5 h to 2.5 h for all workpieces (Cavidade Fixa, Cavidade Movel,
Mandíbula)
 Sufficient lubrication (at least MQL - Minimal Quantity Lubrication) should be used when
machining hardened tool steel
 Copper (electrodes) should be machined without lubrication but sharp cutting edges
(no coating, polished flutes)
 Machining time for electrodes (1 of 3 required setups) exceeds the entire fabrication of all
workpieces directly in hardened tool steel
 Small angles measured at free form surfaces are challenging to detect by tactile
measurement tips. However, using optical measurement equipment helps to better detect
smallest features.
 High surface quality and accuracy in shape can be achieved. Limitations occur at strong free
forms (simultaneous multi-axis machining) and especially due to tool wear.
 Almost relevant micro structures can be manufactured by micro milling. However bore-
holes where very small tolerances are required should be manufactured by EDM processes.
 This process chain 1 in combination with some workpiece preparations and EDM processes
can be seen as very well suited in order to produce the molds. The combination comprises:
o Workpiece Preparation (Miling, Drilling, Grinding, Tapping).
o Micro Milling of Micro Structures
o EDM of Fittings and boreholes
31
4. Process Chain 2
4.1. Wire-EDM Machine Tools

The necessary workpiece preparations were carried out on an AGIE–AC-Vertex 1F and an AGIE-
AC-Evolution 2SFF. The AGIE-AC-Vertex 1F enables better processing concerning specifications
such as geometry feature accuracy and surface roughness. Due to that all features were
machined on the AGIE–AC-Vertex 1F, except one detail whose characteristics required the
extended variety of limitations of the AGIE-AC-Evolution 2SFF.
Figure 4-1: Electrical discharge machine tool AGIE–AC–Vertex 1F
Table 4-1: Technical data of AGIE–AC–Vertex 1F

specification
workspace (dimensions) 300 mm x 200 mm x 80 mm
max. draft angle / height ± 3°/ 80 mm
max. mass / workpiece 35 kg
Twinwire-System using wire electrode diameters 0.02 mm – 0.2 mm
dielectric fluid deionized water
accuracy 0.8 µm
roughness Ra 0.05 µm
32
Figure 4-2: Electrical Discharge Machine AGIE-AC-Evolution 2SFF
Table 4-2: Technical data of AGIE-AC-Evolution 2SFF

specification
workspace (dimensions) 750 mm x 550 mm x 250 mm
max. draft angle / height ± 30°/ 100 mm
max. mass / workpiece 200 kg
usable wire electrode diameters 0.03 mm – 0.3 mm
dielectric fluid deionized water
accuracy 5 µm
roughness Ra 0.2 µm
4.2. Wire Electrodes

The following two wire electrodes were used for the different W-EDM- processes.
Figure 4-3: Bedra – Microcut 0.1 mm – EDM wire
33
The Bedra Microcut 0.1 mm wire electrode was only used for machining on the AGIE-AC-Vertex
1F.
Table 4-3: Bedra Microcut 0,1 mm
electrode data
,anufacturer Bedra
wire name Microcut
wire diameter 0.1 mm
core material brass CuZn36
coating material Zinc
tensile strength 1,000 MPa
max. elastic stretching 1%
Figure 4-4: Bedra – Cobracut Typ1 – EDM wire
The wire electrode Bedra Cobracut Typ 1 was the standard tool electrode for machining on the
AGIE-AC-Evolution 2SFF.
Table 4-4: Bedra Cobracut Typ 1
eectrode data
manufacturer Bedra
wire name Cobracut Typ A
wire diameter 0.25 mm
core material Brass CuZn36
coating material Zinc
tensile strength 900 MPa

max. elastic stretching 1%
34
4.3. Workpiece Clamping

The workpiece was clamped using a horizontal 3R-clamping-chuck. The workpiece position was
measured using the machine correction system. It enables to register the six necessary
parameters that define the explicit position of the workpiece in reference to the machine
coordinate system.
4
1
3
2
1
1
4 1
1
1. machine table 1
2. workpiece
3. clamping device (System 3R)
4. upper / lower head
Figure 4-5: Workpiece clamping
35
4.4. Wire Electrical Discharge Machining (W-EDM) - Process Parameters

The following tables present the most important parameters for the electric discharge process.
The parameters could only be described qualitatively as there exists no equivalence from the
machine´s parameter scale to physical values. Even the parameter´s values of the two applied
machine tools could not be compared.
Table 4-5: Cavidade Fixa – Feature 1_08
cutting step
parameter symbol unit main
trim cut 1 trim cut 2 trim cut 3 trim cut 4
vut
generator mode M - 0 M2 M2 M2 -
discharge current I - 14 13 11 5 -
discharge power P - 20 34 20 35 -
idle-discharge-ratio Ssoll - 65 36 44 - -
short circuit current
reduction ISH - -3 0 - - -
feed mode Reg - 0 1 1 1 -
discharge duration Ton - - - 6 5 -
adaptive corner strategy Str - 0 0 0 0 -
adaptive feed control ACC/ACO - - - - - -
flushing mode Q - 13 13 13 13 -
flushing pressure p bar 5 0.5 0.5 0.5 -
bath type B - 1 1 1 1 -
wire tension force FW N 13 13 13 13 -
wire advance speed AW mm/s 120 120 120 120 -
dieletric conductivity K µSm 10 10 10 10 -
temperature T °C 20 20 20 20 -
offset Ofs µm 247 157 134 128 -
Feature 1_08 had to be machined on the AGIE-AC-Evolution 2SFF due to its 20° angle. Possible
conic angles were limited to 3° on the AGIE–AC-Vertex 1F.
The machining was accomplished with a main cut and three trim cuts. The trim cuts were
performed with the generator mode M2 that enables relaxation discharges. Thereby the
resulting surface roughness is considerably improved. The resulting discharge energy was
continuously reduced from one trim cut to the next to optimize the machined surface quality.
The machining time was about one hour in average. All other features were made on the AGIE–
AC-Vertex 1F.
36
Table 4-6: Mandíblua – Feature 3_03
cutting ctep
cut
generator mode M - 0 - - - -
discharge current I - 8 - - - -
discharge power P - 35 - - - -
idle-discharge-ratio Ssoll - 35 - - - -
reduction ISH - -5 - - - -
feed mode Reg - 0 - - - -
discharge duration Ton - 32 - - - -
adaptive corner strategy Str - 33 - - - -
adaptive feed control ACC/ACO - C - - - -
flushing mode Q - M13 - - - -
flushing pressure p bar 4 - - - -
bath type B - 1 - - - -
wire tension force FW N 2.8 - - - -
wire advance speed AW mm/s 105 - - - -
dieletric conductivity K µSm 5 - - - -
temperature T °C 20 - - - -
offset Ofs µm 665 - - - -
The machining of feature 3_03 was performed with a single main cut. It took about half an hour
due to relatively low discharge energy in order to machine a sufficient surface quality. The
parameter I-Short describes the reduction of the parameter current if a short circuit occurs.
Table 4-7: Mandíblua 20° - Feature 3_01
cutting ctep
cut
generator mode M - 0 10 30 30 30
discharge current I - 10 2 3 2 1
discharge power P - 47 69 - - -
idle-discharge-ratio Ssoll - 20 12 50 20 70
feed mode Reg - 0 F13 F13 F13 30
adaptive corner strategy Str - 33 0 0 0 71
adaptive feed control ACC/ACO - C C - - -
flushing mode Q - M13 T13 T13 T13 T13
flushing pressure p bar 6 0.8 0.7 2 0.7
bath type B - 1 1 1 1 1
wire tension force FW N 3 3 3 3 3
wire advance speed AW mm/s 105 105 105 105 105
dieletric conductivity K µSm 5 5 5 5 5
temperature T °C 20 20 20 20 20
offset Ofs µm 1230 745 574 525 500
37
Feature 3_01 required high surface quality. Therefore the machining was realized with a main
cut and four trim cuts. This took about one hour in average.
Table 4-8: Widening 1.5 mm – Feature 1_06_05 and 3_09
cutting ctep
cut
bath type B - 1 - - - -
38
The features 1_06_05 and 3_09 are ISO fit H6 and were machined with the same parameters as
the feature 3_03 in a single main cut. The processing time was about half an hour.
Table 4-9: Widening 3 mm – Feature 2_11_2
cutting ctep
cut
bath type B - 1 - - - -
39
The same applies for the machining of feature 2_11_2. The only difference is the used offset.
Table 4-10: Ejector pins – Feature 6_01 and 6_02
cutting ctep
cut
bath type B - 1 - - - -
Feature 6_01 and 6_02 of the ejector pins were realized with a single main cut, too. The
machining of one feature took about one hour. The only difference to the two previous sets of
parameters was the applied offset.
40
4.5. EDM Machine Tools – Die Sinking

The applied machine tools were a Zimmer & Kreim Genius 1000 The Cube (Figure 4-6) and an
Agie Agietron Compact 1µ (Figure 4-7).
Figure 4-6: EDM machine tool: Zimmer & Kreim Genius 1000 The Cube
Table 4-11: Technical data of Zimmer & Kreim Genius 1000 The Cube
specification value
construction space 700 mm x 500 mm x 500 mm

current 0.1 A- 47 A
weight of workpiece up to1500 kg
weight of electrode 100 kg / 50 kg (rotation)
dielectric IonoPlus IME- MH
accuracy 0.87 µm/ 700 mm
roughness Ra < 0.08 µm
41
Figure 4-7: EDM machine tool machine Agietron Compact 1µ
Table 4-12: Technical data of Agietron Compact 1µ
specification Value
construction space 250 mm x 160 mm x 250 mm

current 0.8 A- 37.1 A
weight of workpiece up to 200 kg
weight of electrode 70 kg
dielectric Finishing oil IME 63
accuracy < 3 µm
roughness Ra < 0.2 µm
4.6. EDM Tools

The utilities used on the “Agietron Compact 1µ” are intended for the machining of small
through holes. The multichannel tubular electrodes guarantee a stable process by applying an
interior flushing. The hydraulic pump provides a pressure between 10 and 200 bar.
Devices like the microscope and the dial gauge were used to calibrate other devices like bench
vise, which fixes the workpiece, or the electrode guide.
42
1 - hydraulic pump (10- 200 bar)

2 - overhang arm with electrode guides in
3 ceramic (diameter 0.918 mm)
3 – microscope
1 4 4 - dial gauge
5 - bench vise
6 - rotation spindle
7 - multichannel tubular electrodes in
copper (diameter 0.9 mm)
Figure 4-8: Agietron Compact 1µ - components
The actual injection molds were machined on the “Zimmer & Kreim Genius 1000 The Cube”.
The through holes provided better conditions cause of transporting the abrade particles.
The workpiece and the electrodes were calibrated with the help of two measuring probe heads.
The macro measuring probe head was used as the basic reference coordinate system. The
smaller one helped to exactly measure the location of workpieces and electrodes in the
construction room and also to measure their angles.
Figure 4-9 shows the calibrating of a tool electrode. The two upper depictions describe the
measuring of X , Y and Z offsets and the biggest picture shows the compensation of rotation
angle which builds up while fixing the electrode in the tool clamping system. The angle of the
tool electrode was compensated until the measuring cycle resulted in an angle smaller than
0.005 °. This was necessary because of having just a short distance for measuring the angle.
43
Figure 4-9: Calibrating tool electrode
The tool electrodes themselves are presented in the following illustrations. They posess different
undersize due to their planned process inset (roughing 70 µm, smoothing 20 µm, polishing
5 µm). The cylindrical polishing electrodes had an additional undersize of 200 µm in diameter for
an expanding process. In case the rotation angle of the tool electrodes was important to the
machining process they had an additional cuboid for measurement of the angle (Figure 4-9,
Figure 4-10)
Figure 4-10: Applied tool electrodes
44
4.7. EDM - Process Parameters

The following tables present the most important parameters for the electrical discharge process
in its four applied varieties. The first set of parameters describes the machining of through holes
at the Agietron Compact 1µ.
The machining of through holes on the Agietron Compact 1µ took 12 minutes in average. A
high tool wear was accepted due to less process time. The relative tool wear was in a range
from 200 % which means that for a 20 mm hole the programmed erosion depth was more than
60 mm.
The through holes with a 20° angle in the Cavidade Fixa were machined with the help of two
metal angles placed below the workpiece. There was no need for high accuracy in machining
the through holes because the following widening would compensate any errors.
Table 4-13: Parameters for the machining of through holes
process parameter value

impulse duration 56 µs
pause duration 42 µs
discharge current 18.3 A
discharge voltage 160 V
polarity Positive
compression 1
gain 14
pressure 60 bar
rotation speed 300 1/min
The following three different processes on the Zimmer und Kreim Genius were exerted for a
shorter machining time while machining the shape contour and achieving a high surface quality
with the last steps.
Table 4-14: Parameters for roughing processes

c- module Not active
o- module Not active
polarity Positive
erosion time 0.5 s
lift length 2 mm
aimed surface roughness / VDI Class 2.5 µm / 28
The first idea was to install one roughing electrode for each cavity. This was optimized after the
first trials with very little relative tool wear. Three roughing electrodes were sufficient to prepare
eight cavities for the following smoothing process in the Cavidade Movel (Feature 2_06/2_07).
The erosion depth in the roughing process was reduced by 35 µm so the following smoothing
45
process would surely erode enough material for preparing the polishing process. In the
smoothing process every cavity was handled with an unused tool electrode. The same applies for
the polishing processes.
Table 4-15: Parameters for smoothing processes

c- module not active
o- module not active
polarity positive
erosion time 0.5 s
lift length 2 mm
After milling the cast channels (feature 2_05) in the “Cavidade Movel”, the sprue channel
(feature 2_15) could only be machined by EDM. For obtaining less tool wear this process was
accomplished with smoothing parameters causing longer process times (see Figure 4-11). The
angle of 45° was realized with the help of a rotary table from Jauch Schmider.
Figure 4-11: Applied tool electrodes
46
In order to guarantee a real polishing of the cavities surfaces the erosion depth of the smoothing
process was reduced too. In this case the reduction was only 5 µm because too much materials
abrade in polishing would expand process time exponentially respectively the cavity would not
get their correct dimensioning.
Table 4-16: Parameters for polishing processes

c- module not active
o- module active
polarity negative
erosion time 0.4 s
lift length 1 mm
In contrast to the other processes not every polishing process received a target depth but a given
processing time in which the surface should be polished. This time was set at two hours.
Because of having two parts to be polished every cavity had at least 4 hours of polishing time
excluding the time for calibrating the different tool electrodes.
A special focus is to be set on the parameters polarity and o- module. In addition to a significant
lower impulse duration and discharge current, these two parameters generate a high surface
quality. The o- module activates a capacitor which changes the static impulse discharge into a
relaxation discharge. The reversed polarity of the tool causes smaller charge carrier to hit the
workpieces surface.
47
4.8. Process Sequence
Figure 4-12: Process sequences for workpiece 1, 2 and the Mandíbula
48
The following table gives an overview about the average process times for the different cavities.
Table 4-17: Overview about processing times

feature process step process time [min]
1_06 roughing 26.5
smoothing 12.9
polishing 2 x 120
2_06 / 02_07 roughing 37.9 / 46.1
smoothing 17.2 / 21.3
polishing 2 x 120
2_15 smoothing 9.7
3_02 roughing 2.1
smoothing 0.4
polishing 6.6
3_05;3_06;3_07;3_08 roughing 27.3
(mold in Mandíbula) smoothing 4.3
polishing 143.6
The total time required for machining one cavity is about more than six hours including the time
to calibrate the tool electrodes. That means machining the “Cavidade Movel” took about
24 hours.
Figure 4-13: Used and unused tool electrodes (Feature 2_06/2_07)
49
Figure 4-14: Process illustration
The machining of the Cavidade Fixa`s cavities was adapted after having a closer look onto the
cut workpiece. The lower part of the cavity (feature 1_06_03) was not machined. The reason for
that was a too large angle structure of the polishing electrodes.
In order to solve that problem the very low tool wear of the EDM process was helpfull. Thereby
the polishing process could be carried out using the smoothing electrode which showed almost
no wear after eroding a depth of about 35 µm.
This proceeding saved time plus more accuracy because there was no need to calibrate another
tool electrode. The polishing consisting of sinking and following expanding was executed for
four hours.
Having so little tool wear in smoothing also changed the machining of the second Cavidade
Movel. One electrode for roughing two cavities and one for smoothing all four cavities was
sufficient. The polishing processes needed two tool electrodes due to the form of the cavities, a
cylindrical one for the upper contour and another for the lower part.
The machining can be improved by applying longer clamping length for the tool electrodes. This
would avoid an oblique position of the electrodes and increase accuracy.
50
4.9. Measurement Results - Process Chain 2
4.9.1. Tactile Measurements – Zeiss: O- Inspect

The majority of the measured features were within the tolerances and a big part of those who
were out of the requirements miss their goals only slightly e. g., Feature 1-08 diameter 1 and
Feature 3-09. These errors probably occur because of inhomogeneities within the workpiece
material. Higher deviations resulted out of process errors such as tool clamping.
Feature 1_01
Feature 1_02
Feature 1_03
Feature 1_04
Feature 1_08
Feature 1_06_01
Feature 1_06_02
Feature 1_06_03
Feature 1_06_04
Feature 1_06_05
Feature 1_09
51
Table 4-18: Measurements Cavidade Fixa V02
designation/feature actual value nominal tol. (-) tol. (+) deviation Error cause
1_01 height 5.0202938 5.000 -0.05 0.05 0.0203 -
1_08 diameter 1 7.9989247 8.000 0 0.009 -0.0011 -
1_08 diameter 2 8.003247 8.000 0 0.009 0.0032 -
1_08 length 1 7.6095083 7.600 0 0.009 0.0095 inhomogeneities
1_08 length 2 7.6019884 7.600 0 0.009 0.0020 -
1_08 angle 1 19.8911181 20.000 -0.3 0.3 -0.1089 -
1_08 angle 2 20.0559754 20.000 -0.3 0.3 0.0560 -
1_08 distance 2 14.2504127 14.283 -0.02 0.02 -0.0326 -
1_03 angle 9.8106315 10.000 -0.3 0.3 -0.1894 -
1_03 angle 9.7219815 10.000 -0.3 0.3 -0.2780 -
1_03 angle 9.8595013 10.000 -0.3 0.3 -0.1405 -
1_03 angle 9.7366232 10.000 -0.3 0.3 -0.2634 -
1_03 length (x) 50.8462014 49.760 -0.02 0.02 1.0862 WP preparation
1_06_2 radius 1 1.8517431 1.879 -0.02 0.02 -0.0273 electrode
1_06_2 radius 2 1.8399366 1.879 -0.02 0.02 -0.0391 electrode
1_06_3 angle 1 1.236514 1.500 -0.3 0.3 -0.2635 -
1_06_3 angle 2 1.1715506 1.500 -0.3 0.3 -0.3284 electrode
1_09_1 diameter 1 1.5056284 1.500 0 0.006 0.0056 -
1_09_1 diameter 2 1.5059972 1.500 0 0.006 0.0060 -
1_06 position 1 (x) 0.010955 0.000 -0.05 0.05 0.0110 -
1_06 position 2 (x) 0.0058955 0.000 -0.05 0.05 0.0059 -
1_06 position 1 (y) -14.997248 -15.000 -0.05 0.05 0.0028 -
1_06 position 2 (y) 15.0096233 15.000 -0.05 0.05 0.0096 -
1_08 zero position 1 -0.0013268 0.000 -0.05 0.05 -0.0013 -
1_08 zero position 2 0.0053944 0.000 -0.05 0.05 0.0054 -
52
Feature 2_01
Feature 2_06
Feature 2_07
(lower cavity)
Feature 2_02
Feature 2_04
Feature 2_06_1
Feature 2_07_1
Feature 2_06_3
Feature 2_07_3
Feature 2_06_4
Feature 2_07_4
Feature 2_06_5
Feature 2_07_5
53
Table 4-19: Measurements Cavidade Movel V02

actual
designation/feature nominal value tolerance (-) tolerance (+) deviation Error cause
2_07_1 diameter 1 5.065 5.065 -0.05 0.05 0.0003 -
2_06_1 diameter 1 5.065 5.086 -0.05 0.05 0.0208 -
2_07_1 diameter 2 5.065 5.076 -0.05 0.05 0.0110 -
2_06_1 diameter 2 5.065 5.089 -0.05 0.05 0.0239 -
2_07_4 angle 1 30.000 29.470 -0.3 0.3 -0.5296 electrode
2_06_4 angle 1 30.000 29.793 -0.3 0.3 -0.2073 -
2_07_4 angle 2 30.000 29.560 -0.3 0.3 -0.4398 electrode
2_06_4 angle 2 30.000 29.561 -0.3 0.3 -0.4394 electrode
2_07_3 distance 1 (x) 4.250 4.258 -0.05 0.05 0.0080 -
2_06_3 distance 1 (x) 4.250 4.203 -0.05 0.05 -0.0474 -
2_07_3 distance 2 (x) 4.250 4.261 -0.05 0.05 0.0106 -
2_06_3 distance 2 (x) 4.250 4.202 -0.05 0.05 -0.0479 -
2_07_3 distance 1 (y) 4.250 4.252 -0.05 0.05 0.0024 -
2_06_3 distance 1 (y) 4.250 4.215 -0.05 0.05 -0.0353 -
2_07_3 distance 2 (y) 4.250 4.252 -0.05 0.05 0.0024 -
2_06_3 distance 2 (y) 4.250 4.221 -0.05 0.05 -0.0286 -
2_09_1 diameter 1 3.000 3.002 0 0.006 0.0018 -
2_09_1 diameter 2 3.000 3.004 0 0.006 0.0035 -
2_09_1 diameter 3 3.000 3.001 0 0.006 0.0014 -
2_09_5 diameter 4 3.000 3.003 0 0.006 0.0032 -
2_07 position 1 (x) -15.000 -15.009 -0.05 0.05 -0.0095 -
2_06 position 1 (x) 0.000 0.0042 -0.05 0.05 0.0042 -
2_07 position 2 (x) 15.000 14.991 -0.05 0.05 -0.0086 -
2_06 position 2 (x) 0.000 -0.012 -0.05 0.05 -0.0117 -
2_07 position 1 (y) 0.000 0.026 -0.05 0.05 0.0264 -
2_06 position 1 (y) -15.000 -14.990 -0.05 0.05 0.0097 -
2_07 position 2 (y) 0.000 0.0236 -0.05 0.05 0.0236 -
2_06 position 2 (y) 15.000 15.019 -0.05 0.05 0.0191 -
2_02 length (x) -24.970 -25.077 -0.05 0.05 -0.1071 WP preparation
2_02 length (x) 24.970 25.269 -0.05 0.05 0.2997 WP preparation
2_02 length (y) -24.970 -25.134 -0.05 0.05 -0.1640 WP preparation
2_01-2_04 distance 5.500 4.506 -0.05 0.05 -0.9940 WP preparation
54
Feature 3_01
Feature 3_02
Feature 3_03
Feature 3_04
Feature 3_06
Feature 3_07
Feature 3_09
Figure 4-17: Mandíbula features
Table 4-20: Measurements Mandíbula V01
Feature actual value nominal tolerance (-) tolerance (+) deviation Error cause
3_04 diameter 7.993 8.000 -0.009 -0.005 -0.0075 -
3_01 angle 20.007 20.000 -0.3 0.3 0.0074 -
3_02 radius 1.429 1.500 -0.05 0.05 -0.0707 undersized tool
3_07 angle 1.620 1.500 -0.3 0.3 0.1198 -
3_09 diameter 1.513 1.500 0 0.006 0.0131 inhomogeneities
3_06 angle 11.250 10.320 -0.3 0.3 0.9300 electrode
3_06 angle 63.053 63.610 -0.3 0.3 -0.5575 electrode
3_03 distance 7.5913 7.600 -0.009 -0.005 -0.0087 -
The deviation in feature 3_02 occurred because of using only a roughing electrode (70 µm
undersize) for a combined roughing and smoothing process.
55
4.9.2. Optical Measurements - Alicona InfiniteFocus

The measurements on the Alicona Infinite Focus considered only the opened cavities from first
machined cavidades (V01). The following figures show the feature assignment on the left and
the 3D-data of the sliced cavities on the right.
Table 4-21: Measurements Cavidade Fixa V01

Feature 1.06.1-1 5.078 mm 5.065 mm 0.02 mm -0.02 mm 0.013 mm
Feature 1.06.1-2 0.518 mm 0.507 mm 0.02 mm -0.02 mm 0.011 mm
Feature 1.06.3 2.87 ° 3° 0.3 ° -0.3 ° -0.13 °
Feature 1.06.4 59.978 ° 60° 0.3 ° -0.3 ° -0.022 °
Table 4-22: Measurements Cavidade Movel V01

Feature 2.06.4 30.17 ° 30 ° 0.3 ° -0.3 ° 0.17 °
56
Figure 4-20: Mandíbula Features
Table 4-23: Measurements Mandíbula V01
Features actual nominal upper tol. lower tol. deviation

Feature 3.01 19.95 ° 20 ° 0.3 ° -0.3 ° -0.05 °
Feature 3.02 1.513 mm 1.5 mm 0.05 mm -0.05 mm 0.013 mm
Feature 3.05 0.347 mm 0.343 mm 0.05 mm -0.05 mm 0.004 mm
Feature 3.07 3.093 ° 3° 0.3 ° -0.3 ° 0.093 °
Feature 3.08 60.220 ° 60 ° 0.3 ° -0.3 ° 0.22 °
All features measured on the Alicona Infinite Focus were within the acquired tolerances.
4.9.3. Tactile Measurements - Hommel Nanoscan

There were no surface roughness measurements for Cavidade Fixa as the Cavidade Fixa V01
showed errors in the polishing process. The Cavidade Fixa V02 could not be cut as an intact
mold as required.
Table 4-24: Surface Roughness Cavidade Movel
Roughness Ra [µm]
Features longitudinal transversal required
2_01 0.035 0.123 < 0.2 µm
2_06_1 0.191 < 0.2 µm
2_06_4 0.336 < 0.2 µm
2_07_1 0.181 < 0.2 µm
2_07_4 0.191 < 0.2 µm
The results of the Mandíbula can be improved by better accuracy in setting the electrodes by
applying a longer clamping. Additionally these measurements are of the first trials eroding this
cavity. A longer polishing process may improve these results.
Table 4-25: Surface Roughness Mandíbula
Roughness Ra [µm]
Features longitudinal transversal required
3_06 0.427 1.975 < 0.2 µm
57
5. Process Chain 3
In the following section machines, tools, process parameters and strategies used for the
fabrication of the Mold 1 by the Process Chain 3 are presented.
5.1. SLM Workflow

Within the framework of SENAI-Project the mold tools were processed in several iterations to
achieve the required high quality. It was necessary to adopt the CAD data of tools to ensure a
stable SLM build process with simultaneous consideration of finishing processes. Furthermore,
the proper powder material was selected to accommodate different requirements of the
injection molding process. For the purposes of quality control there were performed the powder
analysis and the validation of generated molds. The complete overview of the workflow within
the SLM-Process chain is illustrated in Figure 5-1.
6.3 Selection of 6.4 Analysis of Micro

powder material powder material Milling
6.7 SLM- 6.8 Post- 6.10 Mold
Process Process validation
6.5 Data adaptation 6.6 Data preparation Precision
in CAE environment in RP environment Grinding
6.9 Iteration steps
Figure 5-1: SLM Workflow within the frame of the project
58
5.2. Selective Laser Melting Machine Tool

The applied machine tool was a generative Selective Laser Melting System 250HL (see Figure 5-2).
It produces metal components by using fine metal powders (stainless steel, tool steel, cobalt-
chromium, super alloys, aluminum and titanium) within a material density nearly to 100 %. On
the basis of a 3D CAD data the geometry of tools or components is built up in 20 to 100 µm
layers. Further technical data is listed in Table 5-1.
Figure 5-2: Selective Laser Melting Machine Tool – SLM 250HL
Table 5-1: System parameters of SLM 250HL
parameters values
build chamber 250 mm x 250 mm x 350 mm
laser power (cw) 400 W
focus diameter 70 … 300 µm
layer thickness 20 … 100 µm
build speed rate 5 … 20 cm³/h
tolerance ± 40 µm (x, y, z)
roughness Rz_horizontal = 40 µm
Rz_vertical = 62 µm
59
5.3. Selection of Powder Material

Central requirements, such as wear resistance, toughness, corrosion resistance and polishability
can be defined on a mold tool material. In high-tech mold making are often applied special
mold steels like Böhler M340 to fulfill the demands by trimming the material properties towards
the intended use. A comparable alternative in additive manufacturing is the qualified powder
material 1.2709 (tool steel), which was used for generation of molds within the frame of SENAI-
Project. The comparison of physical properties and chemical composition of both materials is
represented in Table 5-2 and Table 5-3.
The strength values of both materials are approximately identical, so that conventional mould
steel can be substituted by 1.2709 tool steel in case of tool manufacturing.
Table 5-2: Physical Properties of 1.2709 and Böhler M340
physical properties 1.2709 Böhler M340

density [kg/m³] 8042 7700
modulus of elasticity 103 [N/mm²] 217.55 219
tensile strength Rm [MPa] 1110±30 1040±60
yield strength Rp0.2 [MPa] 985±30 900
thermal conductivity [W/mK] 15 18.2
specific heat capacity [J/kg*K] - 460
specific electrical resistance [Ohm*mm²/m] - 0.8
magnetizability available available
Table 5-3: Chemical Composition of 1.2709 and Böhler M340
Chemical composition 1.2709 Böhler M340

C [%] 0.02 0.54
Si [%] 0.13 0.45
Mn [%] 0.08 0.40
Cr [%] 0.12 17.30
Mo [%] 4.89 1.10
V [%] - 0.10
Ni [%] 19.27 -
Ti [%] 0.836 -
Co [%] 7.09 -
Al [%]- 0.094 -
P [%] 0.004 -
S [%] 0.003 -
60
5.4. Analysis of the Powder Material 1.2709

In order to determine the powder material properties of tool steel 1.2709 there were
implemeted a number of examinations. The following presents the results of executed powder
analysis.
Sieve analysis was carried out according to DIN ISO 4497. The tool steel powder had a Gaussian
particle size distribution at interval of 20…63 µm (see Figure 5-3 ). The expected value of the
average grain size was about 30 µm.
dry sieving:
DIN ISO 4497
instruments:
% by weight
Haver EML 200 digital

Kern PLS 1200-3A
test conditions:
powder amount 100 g
amplitude 1,2 g
sieving time 30 min
interval 10 s
fractions
Figure 5-3: Grain size distribution of 1.2709
Filling ratio and packing density of 1.2709 powder were measured by means of funnel method
respectively to DIN EN ISO 3923-1. The results of the testing are summarized in Table 5-4.
Table 5-4: Density of 1.2709
powder material physical density [g/cm³] filling ratio [g/cm³] packing density [%]
1.2709 8.042 4.1 51
The residual moisture content of the tool steel powder was determined before the tests with
0.032 %.
Determination of the flow rate in accordance with DIN EN ISO 4490 by using a funnel diameter
of 3.5 mm. The input quantity of 50 g flowed on average within 5.7 s.
Observation by scanning electron microscope showed that the tool steel powder had
approximately a spherical shape. Furthermore the grain surface was smooth with only few
satellite particles (see Figure 5-4).
61
Figure 5-4: Grain shape of 1.2709
X-ray spectroscopy was used for examination of the chemical composition of powder material.
The percentage of each element is listed in Table 5-5.
elements % by weight atomic %

C 0.00 0.00
Al 0.22 0.48
Si 0.16 0.32
Ti 1.51 1.80
Cr 0.20 0.22
Mn 0.19 0.19
Fe 68.81 70.57
Co 9.59 9.32
Ni 14.70 14.34
Mo 4.62 2.76
∑ 100.00 100.00
Table 5-5: X-ray spectroscopy of 1.2709
62
The analyses of the powder resulted in complete fulfillment of requirements on powder

(see Table 5-6). Consequently is the available tool steel powder suitable to be processed by
selective laser melting under stable conditions.
Table 5-6: Degree of fulfillment of the requirements on powder material

requirements on powder fulfillment
very good flowability of powder: 

- low flow rate 
- spherical grain shape 
- residual moisture content << 1 % 
high packing density > 60 % of powder: •

- max. grain size < 4/3 of layer thickness 
- normal grain size distribution 10…50 µm 
- smooth grain surface without satellite particles 
exact chemical composition of powder: 

- homogeneous microstructure 
fulfilled  partially fullfiled • not fulfilled −
63
5.5. Data Processing in CAE Environment

Initially all necessary parts (see Figure 5-5):
- Cavidade Fixa,
- Cavidade Movel and
- Mandíbula
were isolated for further data adaptation steps in terms of SLM-Preprocessing.
3. Mandíbula (P14)
1. Cavidade Fixa (P11)
2. Cavidade Movel (P10)
Figure 5-5: Left: total assembly of injection molding tools; right: isolated components
Cavidade Fixa was adapted for the purposes of stable Selective Laser Melting building process
and required Post-Processing steps such as milling, drilling and grinding (see Figure 5-6).
Table 5-7 shows step-by-step all implemented modification steps from the raw state until the
completed data item.
64
original model
22 mm adapted model
Figure 5-6: Adaptation of Cavidade Fixa by CAE (SolidWorks 2013)
65
Table 5-7: Adaptation steps of Cavidade Fixa by CAE (SolidWorks 2013)

CAD-Model detailed description
- 0.11 mm offset on the functional surface (cavity)
Feature 1_06_01
Feature 1_06_02
Feature 1_06_03
Feature 1_06_04
Feature 1_06_05
- 0.11 mm offset of the recess for Mandíbula

Feature 1_08
- merge of parts (boolean operation)
- 0.11 mm offset on the supporting surface

Feature 1_02
Feature 1_03
Feature 1_04
- elimination of the bevel
66

- 12.5 mm extrusion to fill the horizontal holes
Feature 1_10_1
Feature 1_10_2
Feature 1_10_3
- 2 mm Ø centering for the horizontal holes
- 15 mm extrusion to fill the vertical holes

Feature 1_10_1
Feature 1_10_2
- 1 mm Ø centering for the vertical holes
- extrusion of 1.5 mm Ø holes till outer surface

Feature 1_09_02
67
Similar adaptation steps were executed with Cavidade Movel in consideration of Selective Laser
Melting building-process and required post-processes (milling, drilling, grinding). Structural step-
by-step changes are illustrated in Figure 5-7 and Table 5-8.
original model
adapted model
22,11 mm
Figure 5-7: Adaptation of Cavidade Movel by CAE (SolidWorks 2013)
68
Table 5-8: Adaptation Steps of Cavidade Movel by CAE (SolidWorks 2013)

CAD-Model Detailed description
Feature 2_06_1 Feature 2_07_1
- merge of parts (boolean operation)
- elimination of the bevel
- 0.11 mm offset on the supporting surface

Feature 2_01
Feature 2_02
Feature 2_03
- 15 mm extrusion to fill the vertical holes

Feature 2_14_1
Feature 2_14_2
69

- 1 mm Ø centering for the vertical holes
- 12.5 mm extrusion to fill the horizontal holes

Feature 2_12_1
Feature 2_12_2
Feature 2_12_3
- 2 mm Ø centering for the horizontal holes
Step-by-step adaptation steps of the cavity pin Mandíbula are pictured in Figure 5-8 and Table
5-9.
original model adapted model
Figure 5-8: Adaptation of Mandíbula by CAE (SolidWorks 2013)
70
Table 5-9: Adaptation Steps of Mandíbula by CAE (SolidWorks 2013)

CAD-Model Detailed Description
Feature 3_05
Feature 3_06
Feature 3_07
Feature 3_08
- 25 mm extrusion of the Mandíbula profile (for clamping)
- self-supporting transition (60° angle) between the holes

Feature 3_10
Feature 3_11
- 0.11 mm offset on the outer surface

Feature 3_03
Feature 3_04
71
After complete CAD data adaptation the molds were exported into a SLT format. The advantage
of the STL formulation is that the triangles can be varied in size for any given geometry and the
file can be adapted to the needed accuracy requirements. Reducing the amount of triangles also
reduces the file size, but the accuracy of the part will decrease and vice versa. Furthermore the
triangle can easily be cut at any desired coordinate, which opens up the opportunity to slice the
STL data according to the layer thickness that will be fabricated by the AM process.
The setting of export parameters in order to achieve a satisfactory part quality is presented in
Figure 5-9. These settings are valid for the CAE SolidWorks software system.
Level of resolution: very fine

Input data: deviation: 0,0248 mm
angle: 2°
Output data: triangles: 82’500
file size: 3,8 MB
Figure 5-9: STL export settings
5.6. Data Preparation in RP Environment

The generated .STL-Files need to be transformed in a compatible data set, which can be
imported by SLM 250HL machinery. This data transformation was carried out as follows:
- creation of 2 mm offset on the base area of molds (considering the separation of build
parts from the substrate plate by a wire-cut EDM, see Figure 5-10)
- positioning of parts in coordinate system of virtual building space
- Repair of STL-data errors
- generation of support structures if necessary
2 mm 2 mm offset for
2 mm offset for
EDM Post-Processing Offset EDM Post-Processing
Figure 5-10: Data preparation in additive manufacturing environment (Magics 16.0)
STL data retrieved from professionally operated CAD systems may include mistakes, which
should be repaired with the repair tool integrated in the software used for AM file preparation.
Because of frequent 3D data transfer between different CAD systems in case of molds, mistakes
72
are likely to occur. The consequences of gaps and intersection of triangles can have enormous
impact on incorrectly calculated tool path for the layer, unstable building process or possible
stop of the unfinished build. The most common mistakes are shown in Figure 5-11.
gap overlapping triangles wrong orientation
Figure 5-11: Most frequent errors in STL files
Further steps complete the data preparation process:
- fefinition of SLM process parameters

- slicing (50 micron layer thickness)
- hatching (chessboard)
- final positioning of injection molding tools on virtual platform (see Figure 5-12)
Chessboard hatching was chosen as the exposure strategy. As a result the whole layer is
subdivided into several exposure fields, which are defined by parameters, such as field size, line
spacing and incrementing angle.
Figure 5-12: Hatching and positioning in additive manufacturing environment (Autofab 1.6)
73
5.7. SLM Build Process

In order to achieve a stable SLM building process qualified parameters of 1.2709 were applied.
These are listed detailed in Table 5-10.
Table 5-10: Applied parameter settings for building the mold tools
parameter settings of 1.2709 powder material unit value

Shrinkage XY % 0.113
shrink factor
Shrinkage in Z % 0.113
velocity mm/s 400
contour power W 100
focus mm 1
velocity mm/s 810
chessboard hatching W
hatch power W 275
laser parameters
focus mm 2
velocity mm/s 450
contour offset power W 150
focus mm 1
spot compensation mm 0.09
contour distances mm 0.09
number of contour path - 2
check number of layers - 50
shift of starting point
minimal point distance mm 1
width of the field mm 5
height of the field mm 5
hatch mm
field overlap 0
chessboard
minimal field size mm 2.5
chessboard hatching contour spacing mm 0.15
exposure parameters angle ° 45
meander hatching, blocks - -
hatch °
angle incrementation 90
black fields
line spacing mm 0.12
contour spacing mm 0.02
angle ° 135
meander hatching, blocks - -
hatch °
angle incrementation 90
white Fields
line spacing mm 0.12
contour spacing mm 0.02
layer thickness µm 50
5.8. SLM Post-Processing

After removing of build parts (see Figure 5-13) followed the post-processes to separate the tools
from the substrate plate and clean their surface. The precise separation of generated parts and
plate was occurred by means of EDM. Afterwards the molds were cleaned by glass-bead-
blasting method to remove the residual powder and powder adhesion.
74
Figure 5-13: Generated parts
5.9. Iteration Steps

To achieve the required mold quality there were executed three iteration steps. The detailed
overview of each step and the respective improvements are given in Figure 5-14.
Mold
V01
Step 1:
Adaptation of CAD model to
avoid support structures by
better heat dissipation
Mold
V02
Step 2:
Increase of powder coating
quality during the build process
by free coat track per each part
Mold
V03
Step 3:
Increase of material offset
Analysis of part shrinkage
Analysis of dimensional accuracy
Mold
V04
Figure 5-14: Executed iteration steps
75
5.10. Mold Validation

The surface condition of molds was detected by roughness measurement system HOMMEL
Nanoscan 855 (Figure 2-8). Roughness Rz averaged about 60 µm. Ra was below the value of
10 µm. These dimensions are typical for powder based process such as SLM.
An optical measuring technique (see Figure 2-9) was applied to analyze the dimensional
accuracy of mold tools. The further goal was the correction of material shrink factor. This
process parameter determines the material expansion in each direction during the building
process.
Optical measurement
Instruments:
ATOS 3 400 SN
Test conditions:
deviation 0.027 Pixel
scale deviation 0.000 mm
sphere spacing deviation 2 µm
camera lense 40 mm
camera angle 26.95°
height variance 240.56 mm
Figure 5-15: Optical Measuring of Molds

The material offset in the range of 100…500 µm was determined on outer contour faces of V03
Molds (see Figure 5-16 and Figure 5-17). This fact was induced by incorrect shrink factor, which
was set at 0.113 %. V04 Mold tools were built with reset settings to identify the precise
shrinkage value. After a further calculation the shrinkage was corrected to 0.234 % (see Figure
5-18).
400
µm
-200
-400
Cavidade Movel (P10) Cavidade Fixa (P11)
Figure 5-16: Dimensional accuracy of Molds V03, 3D view
76
400
µm
0
Cavidade Movel (P10)
-200
-400
Cavidade Fixa (P11)
Figure 5-17: Dimensional accuracy of Mold V03 (sectional view)
77
Figure 5-18: Shrink factor calculation of Molds V04

The additional reason for deviation from the nominal dimensions was the suboptimal thermal
management during the building process. The delay time, which defines the period between the
exposure and coating step during the building process, was not long enough. Exposed parts
could not cool down to the temperature level of the substrate plate, which is defined by
preheating up to 200°C.
Layer by layer the contours of Molds expanded in X- and Y-Direction and caused a positive
offset, red color, on the outer surface and a negative offset, blue color, in the inner section of
tools (see Cavidade Fixa in Figure 5-19 and Figure 5-20). The explicit boost of the mentioned
effect was achieved by reduction of exposure area in the upper layers of generated part in cause
of the component geometry.
78
400
µm
-200
-400
Cavidade Movel (P10) Cavidade Fixa (P11)
Figure 5-19: Dimensional accuracy of Molds V04, 3D view
400
µm
0
Cavidade Movel (P10)
-200
-400
Cavidade Fixa (P11)
Figure 5-20: Dimensional accuracy of Molds V04, sectional view
79
5.11. NC-Form Grinding and Milling Machine Tool

The 5- axis- milling and grinding machine tool Röders RXP600DSH UHP was used for machining
of SLM workpieces (Figure 5-21). The technical data of this machine tool are described in Table
5-11.
[Röders]
[Röders]
Figure 5-21: Machine Tool Röders RXP600DSH UHP
Table 5-11: Technical data from Röders RXP600DSH UHP

linear drives max. 60 m/min (lateral axes)
60 rpm A-axis
80 rpm C-axis
spindle MFW1709/30 (optional) power: 22 kW

speed: 100 - 30.000 rpm
internal tool cooling: 80 bar
spindle MFW1224/60 (applied) Power: 8.5 kW

spindle speed: 100 - 60.000 rpm
internal tool cooling: 40 bar
spindle SC1060-0A (optional) Power: 0,5 kW

spindle speed: 60.000 - 160.000 rpm
pivoting/turning range A-axis +/- 115°

C-axis +/- n x 360°
cooling lubricant grinding oil - Oelheld DiaMond 100
80
5.12. Grinding Tools for the Machining of SLM Workpieces

Figure 5-22 shows the most used geometries for the NC-Form grinding. Table 5-12 shows the
specifications of the grinding tools used for machining the Mold 1 by Process Chain 3.
Cylindrical
Spherical
Cylinder Cup shape with Cone
shape
round end
Figure 5-22: Possible geometries for grinding tools for NC-form grinding
Table 5-12: Specification of the used grinding tools
grain grain size bonding diameter shaft

N. format concentration
material [µm] material [mm] [mm]
1 cup CBN 126 V240 galvanic 10 8
2 cylinder CBN 64 V240 vitrified 6 6
3 spherical CBN 91 V240 galvanic 2.9 2
5.13. Machine Tool Setup and Referencing of SLM Workpieces

To guarantee parallel surfaces between the top and the bottom of the mold, the Cavidade
Movel and Cavidade Fixa were ground on these two surfaces (Feature 1.01 and Feature 2.01) in
a conventional surface grinding machine (Figure 5-23). After that, the Cavidade Movel and
Cavidade Fixa were fixed on a clamping system in the Röders machine for the machining of the
mold bodies due to milling and NC-form grinding.
Figure 5-23: Features 1.01 and 2.01 machined by conventional Surface Grinding
A challenge for the post machining of SLM workpieces is the referencing process due to the
high resultant roughness and waviness on the surface of the parts. Some points were acquired
81
on the SLM surface using the tactile measurement system integrated in the machine tool to
referencing the workpieces (Figure 5-24). A deviation of 30 µm could be detected at the
workpiece surface of the SLM parts, which could generate a significant positioning error when a
single point is used as a reference. For this reason, the referencing of the X- and Y- axis was
based on an average value of 50 points.
A
clamping system
workpiece
Z
X
workpiece reference
(machine)
B
60
Position on the Y coordinate
Z
µm
45
Y X
taster
measurement
30
coordinate
15
x x x x x x x x
0 workpiece
0 7 14 mm
21 28
Position on the X coordinate
Figure 5-24: Scheme of the clamping system (A), points from the surface of a SLM workpiece (with
roughness and waviness deviations) (B).
82
5.14. Challenges by machining of SLM workpieces

Four pairs of workpieces (Molds V01, V02, V03 and V04) were produced by SLM (4 x Cavidade
Fixa and 4 x Cavidade Movel). These Molds were machined by grinding, milling and EDM. This
section aims to describe and to give some advices regarding the challenges observed by the
machining of the SLM workpieces. The Mold V04 was the final one, with all needed
compensations by the SLM parameters (Table 5-13).
Table 5-13: Machining of SLM workpieces
Mold V01 Mold V02 Mold V03 Mold V04

try-out model try-out model try-out model final model
look for errors solve the errors solve the errors
The machining of Mold V01 started with milling and grinding of the workpiece 2 (Cavidade
Movel). The first machined feature was the 2.01 following by the 2.04. No problems could be
observed by the machining of these features. After that, the Feature 2.03 was ground. By the
machining of this feature, some deviations were detected regarding the theoretical offset of
0.11 mm applied by the SLM programming. The same could be observed by the machining of
the Feature 2.16.
By the machining of the Cavidade Fixa of the Mold V01, following machining sequence was
applied: Features 1.01, 1.03, 1.04, 1.02, 1.05, 1.14 and 1.13. Because of the shrinkage
generated by the SLM process, no contact was detected between the tool and the workpiece
(Features 1.03 and 1.04 ) when used the CAD/CAM programming Data (theoretical final
dimension) for the machining. After this consideration, the workpiece must be ground with a
higher total depth of cut to achieve a complete machining of the workpiece surface generated
by SLM. This deviation between the programmed and the final machined surface was around
250 µm. It means both SLM workpieces were larger than the drawings (see Figure 5-25).
Mold 1
Real workpiece 1
(Cavidade Fixa)
Theoretical workpiece 1
(Cavidade Fixa)
Theoretical workpiece 2
(Cavidade Móvel)
Real workpiece 2
(Cavidade Móvel)
Figure 5-25: Theoretical and actual workpiece dimension
83
The same deviations were detected for Mold V02.
Real
length
Theoretical
length
workpiece 1
(Cavidade Fixa)
Mold V01
workpiece 2
(Cavidade Móvel)
workpiece 1
(Cavidade Fixa)
Mold V02
workpiece 2
(Cavidade Móvel)
Figure 5-26: Theoretical and real length ground from Mold V01 and Mold V02
The final sequence applied for machining of SLM molds is presented below:
WP1: WP2:
1- Feature 1.01 1- Feature 2.01

2- Feature 1.03 and 1.04 2- Feature 2.04
7- Feature 2.16
84
5.15. Grinding Parameters

Table 5-14 shows the grinding parameters used by machining of the SLM Molds. Some
observations were done to complement the information regarding the fabrication of the SLM
Molds.
Table 5-14: Grinding parameters

grinding spindle feed
infeed cossfeed
WP feature tool rotation rate observations [#]
ae ap
No.r n vf
[rpm] [mm/min] [mm] [mm]
1 1.01 1 50,000 30 full contact 0.010 top grinding with oscillation
[1]
1 1.02 2 50,000 50 0.010 full contact peripheral grinding [2]
1 1.05 3 50,000 50 0.010 0.020 spherical grinding [3]
1 1.14 1 50,000 30 0.020 full contact peripheral oscillating grinding
[5]
2 2.01 1 50,000 30 full contact 0.010 top grinding with oscillation [1]
2 2.04 1 50,000 30 full contact 0.010 top grinding with oscillation [1]
2 2.05 3 50,000 50 0.010 0.020 spherical grinding
2 2.17 1 50,000 30 0.020 Full contact peripheral oscillating grinding
[5]
Table 5-15: List of observations

[1] amplitude of oscillation 10 µm - frequency 20Hz;
[2] The feature was ground until the complete surface resultant from the SLM process was
removed. The material removed was 250 µm;
[3] no significant deviation regarding to the geometry were observed by using ae 0.001 mm,
0.005 mm and 0.010 mm (Figure 5-27, Figure 5-28 and Figure 5-29).
[4] ground until the complete surface resultant from the SLM process was removed;
[5] amplitude of oscillation 18 mm - frequency 2 Hz;
[6] the feature was ground with over material 250 µm, to compensate the over material
removed in Feature 1.02.
85
Figure 5-27: Profile of Feature 1.05 (injection canals) ground with ae = 1 µm (zoom 50x and 5x). The
profile was captured with an InfiniteFocus Measurement System (Alicona).
Figure 5-28: Profile of Feature 1.05 ground with ae = 5 µm (zoom 50x and 5x). The profile was
captured with an InfiniteFocus Measurement System (Alicona).
86
Figure 5-29: Profile of Feature 1.05 ground with ae = 10 µm (zoom 50x and 5x). The profile was
captured with an InfiniteFocus Measurement System (Alicona).
87
5.16. CNC programs and strategy

In this section the grinding strategies applied for the machining of Mold 1 (Cavidade Fixa em
cavidade movel) are presented. All 3- and 5- axis CAD/CAM programming are executed using
the software MasterCam. The tested and used programs for all features can be found in the
media attached.
Table 5-16: Programming and kinematics for the machining of the SLM Molds
Feature 1.01 Feature 1.02

strategy: top surface grinding with oscillation strategy: peripheral surface grinding
number of axis: 3 number of axis: 5
cycle time: 11 min cycle time: 3 min
repetition: 1 repetition: 3
total time: 11 min total time: 9 min
file name: Feature1_01 file name: Feature1_02

strategy: spherical grinding strategy: peripheral surface grinding
88

strategy: peripheral surface oscillating grinding strategy: top surface grinding with
number of axis: 3 oscillation
cycle time: 25 min number of axis: 3
repetition: 3 cycle time: 25 min
total time: 75 min repetition: 1
file name: Feature1_14 total time: 25 min
file name: Feature2_01

strategy: peripheral surface grinding strategy: peripheral surface grinding
89

strategy: Top surface grinding with oscillation strategy: spherical grinding
cycle time: 10 min cycle time: 2min
total time: 30 min total time: 1 h 40 min

strategy: peripheral surface grinding strategy: peripheral surface
number of axis: 5 oscillating grinding
cycle time: 5 min number of axis: 3
repetition: 3 cycle time: 23 min
total time: 15 min repetition: 3
file name: Feature2_16 total time: 69 min
file name: Feature2_17
90
5.17. Results of the Machining Processes within Process Chain 3

The results of the optic measurement by Atos 3400 SN of the mold V04 are shown in Figure
5-30 (Cavidade Fixa) and Figure 5-31 (Cavidade Movel).
Top View
0.200
Deviation Distribution
50.0
mm
%
0.000 25.0
12.5
-0.100
00.0
-0.200 -0.100 0.000 mm 0.200
-0.200
0.200 Optical measurement

Front View Instrument:
ATOS 3 400 SN
mm Test conditions:
Deviation: 0,027 Pixel
Scale deviation: 0,000 mm
0.000 Sphere spacing
deviation: 2 µm
-0.100 Camera lense: 40 mm
Camera angle: 26,95°
-0.200 Heigh variance: 240,56 mm
Figure 5-30: Surface measurement of Cavidade Fixa (V04)
91
Isometric View 0.100

Deviation Distribution
40.0
mm
%
0.000
20.0
10.0
-0.050
00.0
-0.090 -0.035 0.020 mm 0.120
-0.100
Optical measurement
0.100 Instrument:
Front View ATOS 3 400 SN
Test conditions:
mm Deviation: 0,027 Pixel
Scale deviation: 0,000 mm
0.000 Sphere spacing
deviation: 2 µm
Camera lense: 40 mm
-0.050
Camera angle: 26,95°
-0.100 Heigh variance: 240,56 mm
Figure 5-31: Surface Measurement of Cavidade Movel (V04).
For the optic measurement of the cavities the optic measurement system Alicona InfineteFocus,
was used. The workpieces were cut by Wire-EDM. Figure 5-32 shows the measurement of the
cavities.
Feature 2_06_1
Feature 2_07_1
Feature 2_06_2
Feature 2_07_2
Feature 2_06_3
Feature 2_07_3
Feature 2_06_4
Feature 2_07_4
Feature 2_06_5
Feature 2_07_5
Draw Measurement
Feature 2.06.01 5.07 mm 5.0706 mm
Feature 2.06.02 0.41 mm 0.4156 mm
Feature 2.06.03 4.25 mm 4.2342 mm
Feature 2.06.04 30 ° 29.97 °
Feature 2.06.05 4.535 mm 4.5787 mm
Figure 5-32: Results of the EDM machined cavities of the SLM workpieces
92
Table 5-17 shows the results of a tactile measurement system, Zeiss O-Inspect, from the
workpiece Cavidade Fixa.
Table 5-17: Tactile Measurement from the Workpiece Cavidade Fixa V05.
actual
designation/feature value nominal tol. (-) tol. (+) deviation error cause
1 length (x) 59.9368 60.000 -0.018 -0.01 -0.0632 -
1 length (y) 59.9334 60.000 -0.018 -0.01 -0.0666 -
1_01 height 4.9990 5.000 -0.05 0.05 -0.0010 -
1_08 diameter 1 7.9922 8.000 0 0.009 -0.0078
1_08 diameter 2 7.9943 8.000 0 0.009 -0.0057
1_08 length 1 7.5745 7.600 0 0.009 -0.0255
1_08 length 2 7.6097 7.600 0 0.009 0.0097
1_08 angle 1 19.7770 20.000 -0.3 0.3 -0.2230 -
1_08 angle 2 20.0422 20.000 -0.3 0.3 0.0422 -
1_08 distance 1 14.1263 14.283 -0.02 0.02 -0.1567
1_08 distance 2 14.0194 14.283 -0.02 0.02 -0.2636
1_03 angle 10.4190 10.000 -0.3 0.3 0.4190
1_03 angle 10.4225 10.000 -0.3 0.3 0.4225
1_03 angle 10.4670 10.000 -0.3 0.3 0.4670
1_03 angle 10.4853 10.000 -0.3 0.3 0.4853
1_03 length (x) 49.7692 49.760 -0.02 0.02 0.0092 -
1_03 length (y) - 49.760 -0.02 0.02 - no value
1_06_2 radius 1 1.7061 1.879 -0.02 0.02 -0.1729
1_06_2 radius 2 1.8685 1.879 -0.02 0.02 -0.0105 -
1_06_3 angle 1 1.4383 1.500 -0.3 0.3 -0.0617 -
1_06_3 angle 2 1.4714 1.500 -0.3 0.3 -0.0286 -
1_09_1 diameter 1 1.3265 1.500 0 0.006 -0.1735
1_09_1 diameter 2 1.3240 1.500 0 0.006 -0.1760
1_06 position 1 (x) -0.0715 0.000 -0.05 0.05 -0.0715
1_06 position 2 (x) -0.0807 0.000 -0.05 0.05 -0.0807
1_06 position 1 (y) -14.9741 -15.000 -0.05 0.05 0.0259 -
1_06 position 2 (y) 15.0340 15.000 -0.05 0.05 0.0340 -
1_08 zero position 1 0.0487 0.000 -0.05 0.05 0.0487 -
1_08 zero position 2 0.0526 0.000 -0.05 0.05 0.0526
93
Table 5-18 shows the results of a tactile measurement of Cavidade Movel.

Table 5-18: Tactile measurement from the Workpiece Cavidade Movel V05.
designation/feature actual value nominal tol. (-) tol. (+) deviation Error cause
2 length (x) 59.9827 60.000 -0.029 -0.01 -0.0173 -
2 length (y) 59.9847 60.000 -0.029 -0.01 -0.0153 -
2_07_1 diamater 1 5.0538 5.065 -0.05 0.05 -0.0112 -
2_06_1 diamater 1 5.0589 5.065 -0.05 0.05 -0.0061 -
2_07_1 diamater 2 5.0498 5.065 -0.05 0.05 -0.0152 -
2_06_1 diamater 2 5.0578 5.065 -0.05 0.05 -0.0072 -
2_07_4 angle 1 30.3010 30.000 -0.3 0.3 0.3010
2_06_4 angle 1 30.1521 30.000 -0.3 0.3 0.1521 -
2_07_4 angle 2 29.8303 30.000 -0.3 0.3 -0.1697 -
2_06_4 angle 2 30.0604 30.000 -0.3 0.3 0.0604 -
2_07_3 distance 1 (x) 4.2338 4.250 -0.05 0.05 -0.0162 -
2_06_3 distance 1 (x) 4.1666 4.250 -0.05 0.05 -0.0834
2_07_3 distance 2 (x) 4.2381 4.250 -0.05 0.05 -0.0119 -
2_06_3 distance 2 (x) 4.1743 4.250 -0.05 0.05 -0.0757
2_07_3 distance 1 (y) 4.2398 4.250 -0.05 0.05 -0.0102 -
2_06_3 distance 1 (y) 4.1834 4.250 -0.05 0.05 -0.0666
2_07_3 distance 2 (y) 4.2397 4.250 -0.05 0.05 -0.0103 -
2_06_3 distance 2 (y) 4.1915 4.250 -0.05 0.05 -0.0585
2_09_1 diameter 1 2.9998 3.000 0 0.006 -0.0002
2_09_1 diameter 2 3.0000 3.000 0 0.006 0.0000 -
2_09_1 diameter 3 3.0005 3.000 0 0.006 0.0005 -
2_09_5 diameter 4 2.9990 3.000 0 0.006 -0.0010
2_07 position 1 (x) -14.990 -15.000 -0.05 0.05 0.0105 -
2_06 position 1 (x) 0.0175 0.000 -0.05 0.05 0.0175 -
2_07 position 2 (x) 15.0137 15.000 -0.05 0.05 0.0137 -
2_06 position 2 (x) 0.0109 0.000 -0.05 0.05 0.0109 -
2_07 position 1 (y) 0.0042 0.000 -0.05 0.05 0.0042 -
2_06 position 1 (y) -15.000 -15.000 -0.05 0.05 0.0003 -
2_07 position 2 (y) 0.0009 0.000 -0.05 0.05 0.0009 -
2_06 position 2 (y) 15.0062 15.000 -0.05 0.05 0.0062 -
2_02 length (x) -24.975 -24.970 -0.05 0.05 -0.0049 -
2_02 length (x) 24.9382 24.970 -0.05 0.05 -0.0318 -
2_02 length (y) -24.982 -24.970 -0.05 0.05 -0.0120 -
2_02 length (y) 25.0220 24.970 -0.05 0.05 0.0520
2_01-2_04 distance 5.4998 5.500 -0.05 0.05 -0.0002 -
2_02 angle 1 10.0183 10.000 -0.3 0.3 0.0183 -
2_02 angle 2 10.0360 10.000 -0.3 0.3 0.0360 -
2_02 angle 3 9.9902 10.000 -0.3 0.3 -0.0098 -
2_02 angle 4 9.9972 10.000 -0.3 0.3 -0.0028 -
94
5.18. Comparison between Machining Strategies

In this section, tree different machining kinematics are compared. The surfaces topographies
were measured by Alicona according to DIN EN ISO 25178-2. The primary profile, the roughness
and waviness parameters were measured by the tactile system Hommel-Etamic nanoscan855,
according to DIN EN ISO 4287 and DIN EN ISO 4288.
Table 5-19: Compare of different kinematics

milling DIN 8589-3 grinding DIN 8589-11 grinding DIN 8589-11
face milling* face grinding peripheral surface grinding (ex.
(ex. Feature 1.04) (ex. Feature 2.01) Feature 2.17)
Sa = 5.1673 µm Sa = 9.813 µm Sa = 6.4455 µm

Sq = 6.9328 µm Sq = 13.304 µm Sq = 8.9546 µm
Sp = 87.888 µm Sp = 125.01 µm Sp = 100.6 µm
Sv = 206.39 µm Sv = 58.423 µm Sv = 43.809 µm
Sz = 294.28 µm Sz = 183.43 µm Sz = 144.41 µm
Sk = 15.329 µm Sk = 20.251 µm Sk = 17.119 µm
Spk = 9.1674 µm Spk = 26.846 µm Spk = 16.044 µm
Svk = 8.2321 µm Svk = 6.7176 µm Svk = 8.6447 µm
2,2 2,2 2,2
1,1 1,1 1,1
0 0 0
-1,1 -1,1 -1,1
-2,2 -2,2 -2,2

0 1,2 2,4 3,6 4,8 0 1,2 2,4 3,6 4,8 0 1,2 2,4 3,6 4,8
Ra = 0.168 µm Ra = 0.446 µm Ra = 0.414 µm

Rz = 1.935 µm Rz = 1.957 µm Rz = 2.264 µm
Rmax = 2.840 µm Rmax = 2.045 µm Rmax = 3.229 µm
Rt = 3.167 µm Rt = 2.045 µm Rt = 3.278 µm
Rk = 0.458 µm Rk = 0.595 µm Rk = 1.370 µm
Rvk = 0.528 µm Rpk = 1.035 µm Rpk = 0.324 µm
Rpk = 0.191 µm Rvk = 0.082 µm Rvk = 0.682 µm
Wa = 0.127 µm Wa = 0.012 µm Wa = 0.204 µm
Wz = 0.262 µm Wz = 0.025 µm Wz = 0.703 µm
Wt = 0.570 µm Wt = 0.060 µm Wt = 0.873 µm
Pa = 0.233 µm Pa = 0.448 µm Pa = 0.542 µm
Pz = 3.117 µm Pz = 2.044 µm Pz = 3.512 µm
95
*At the Röders machine tool (used at Fraunhofer IPK to machining the SLM workpieces), it is
possible to apply milling to rough the surfaces and grinding for the finishing. Better results of
waviness values of the surfaces could be observed compared to machined surfaces by grinding.
5.19. Comparison between EDM Machining in 1.2709 (SLM) and Böhler M340
The cavities on the SLM parts were produced by EDM. The EDM and micro-milling technologies
are already presented in the Process Chain 2, Chapter 5. The resultant machining time and
workpiece quality by the machining of the cavities by SLM parts (steel 1.2709) were comparable
to the results obtained by the machining of the Böhler M340 (Table 5-20).
Table 5-20: Time comparison of the machined cavities
material feature roughing time [min] smoothing time [min] polishing time [min]
1.2709 (SLM) 1.08 21.76 6.23 2 x 120
Böhler M340 1.08 26.5 12.9 2 x 120
1.2709 (SLM) 2.08 / 2.09 28.76 38.76 2 x 120
Böhler M340 2.08 / 2.09 37.9 / 46.1 17.2 / 21.3 2 x 120
96
6. Appendix A – List of Features
6.1. Cavidade Fixa (P11)
Process Chain 1 Process Chain 2 Process Chain 3

Features 1_01-1_04 Features 1_01-1_04 Features 1_01-1_02
Feature 1_01 • Milling • Milling • Grinding
Features 1_13-1_14 Features 1_13-1_14 Features 1_03-1_04
Feature 1_02 • Milling • Milling • Milling
Features 1_13-1_14
Feature 1_03 • Grinding
Feature 1_04
Feature 1_13
Feature 1_14

Features 1_05 Features 1_05 Features 1_05
• Drilling • Drilling • Drilling
Feature 1_07

Feature 1_06_01 Features 1_06_1-1_06_5 Features 1_06_1-1_06_5 Features 1_06_1-1_06_5
• Milling • EDM • EDM
Feature 1_06_02
Feature 1_06_03
Feature 1_06_04
Feature 1_06_05
97

• Drilling • Drilling • Wire-cut EDM
• Wire-cut EDM • Wire-cut EDM
Feature 1_08
Feature 1_09_01 Features 1_09_1-1_09_2 Features 1_09_1-1_09_2 Features 1_09_1-1_09_2

Feature 1_09_02

Features 1_10_1 Features 1_10_1 Features 1_10_1
Feature 1_10_1
Feature 1_10_2 • Screw thread
• Screw thread • Screw thread

Feature 1_11_1 • Withworth Rc 1/8 • Withworth Rc 1/8 • Withworth Rc 1/8
Features 1_11_2 Features 1_11_2
Feature 1_11_2 • Drilling • Drilling
Features 1_11_3 Features 1_11_3
Feature 1_11_3 • Drilling • Drilling

• Milling • Milling • closed feature
Feature 1_12
98
6.2. Cavidade Movel (P10)

Feature 2_01 Features 2_01-2_04 Features 2_01-2_04 Features 2_01-2_04
• Milling • Milling • Grinding
Feature 2_03
Feature 2_04
Feature 2_16
Feature 2_17

Feature 2_05 Feature 2_05 Feature 2_05 Feature 2_05
(Finishing)
• Milling
(Finishing)

99

Feature 2_06_1 Feature 2_06_1–2_06_5 Feature 2_06_1–2_06_5 Feature 2_06_1–2_06_5
Feature 2_07_1 Feature 2_07_1–2_07_5 Feature 2_07_1–2_07_5 Feature 2_07_1–2_07_5
Feature 2_06_2
Feature 2_07_2
Feature 2_06_3
Feature 2_07_3
Feature 2_06_4
Feature 2_07_4
Feature 2_06_5
Feature 2_07_5

Feature 2_08 Feature 2_08 Feature 2_08
• Milling • Milling • closed feature
Feature 2_08

Feature 2_09_1 Features 2_09_2 Features 2_09_2 Features 2_09_2
Feature 2_09_2

Features 2_10_1-2_10_2 Features 2_10_1-2_10_2 Features 2_10_1-2_10_2
Feature 2_10_1
Feature 1_10_2

Features 2_11_1-2_11_2 Features 2_11_1-2_11_2 Features 2_11_1-2_11_2
Feature 2_11_1
Feature 2_11_2
100

Features 2_12_1 – 2_12_2 Features 2_12_1 – 2_12_2 Features 2_12_3
Feature 2_12_1 • Drilling • Drilling • Drilling
Features 2_12_3 Features 2_12_3 • Withworth Rc 1/8
• Drilling • Drilling
• Withworth Rc 1/8 • Withworth Rc 1/8
Feature 2_12_2
Feature 2_12_3

Feature 2_13 Feature 2_13 Feature 2_13
Feature 2_13

Feature 2_14_1 Feature 2_14_1 Feature 2_14_1 Feature 2_14_1
Feature 2_14_2 Feature 2_14_2 Feature 2_14_2 Feature 2_14_2
• Screw thread • Screw thread • Screw thread

Feature 2_15 Feature 15 Feature 15 Feature 15
101
6.3. Mandíbula (P14)

Feature 3_01 Features 3_01 Features 3_01 out
• Milling • Milling
Feature 3_02 Features 3_02 Features 3_02
Features 3_04 Features 3_04
Feature 3_04 • Milling • Milling

Features 3_05 Features 3_05 out
Feature 3_05 • Milling • EDM
• Milling • EDM
• Milling • EDM
• Milling • EDM
• Drilling • Drilling
Feature 3_09 • Drilling • Drilling
Feature 3_10
102

Features 3_11 Features 3_11 out
Feature 3_11 • Milling • Milling
• Thread • Thread
103

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Technology Guide for Mold 1

» Enhancement of the Technological Excellence of the

Institute for Production Systems and Design Technology

Brazil: David Carlos Domingos

Germany: Frederik Mahr

Berlin, January 28, 2014

1.1. Objective and Tasks of the Project ........................................................................... 4

1.2. Overview about the Technology Guide .................................................................... 4

2. Process Chains and Course of Action ........................................................................... 5

2.1. Components of Mold 1........................................................................................... 6

2.2. Workpiece Preparation............................................................................................ 7

2.3. Measuring Strategies and Equipment ...................................................................... 8

2.3.2. Characteristic Micro-Features for Workpiece Validation ............................................ 11

3. Process Chain 1.............................................................................................................14

3.1. Milling Machine Tool .............................................................................................14

3.2. Milling and Drilling Tools ........................................................................................15

3.3. Milling Strategies ...................................................................................................16

3.3.2. Manufacturing of Cavidade Movel ........................................................................... 18

3.3.3. Manufacturing of Mandíbula ................................................................................... 19

3.3.4. Manufacturing of EDM Electrodes for Process Chain 2 and 3 ................................... 21

3.4. Measurement Results Process Chain 1 ....................................................................23

3.4.2. Optical Measurement Results – Alicona InfiniteFocus................................................ 29

3.5. Tactile Roughness Measurements – Hommel Nanoscan ...........................................31

3.6. Summary of Process Chain 1 ..................................................................................31

4. Process Chain 2.............................................................................................................32

4.1. Wire-EDM Machine Tools .......................................................................................32

4.2. Wire Electrodes......................................................................................................33

4.3. Workpiece Clamping .............................................................................................35

4.4. Wire Electrical Discharge Machining (W-EDM) - Process Parameters .........................36

4.6. EDM Tools .............................................................................................................42

4.7. EDM - Process Parameters ......................................................................................45

4.8. Process Sequence ..................................................................................................48

4.9. Measurement Results - Process Chain 2 ..................................................................51

4.9.2. Optical Measurements - Alicona InfiniteFocus .......................................................... 56

4.9.3. Tactile Measurements - Hommel Nanoscan .............................................................. 57

5. Process Chain 3.............................................................................................................58

5.1. SLM Workflow.......................................................................................................58

5.2. Selective Laser Melting Machine Tool .....................................................................59

5.3. Selection of Powder Material ..................................................................................60

5.4. Analysis of the Powder Material 1.2709..................................................................61

5.5. Data Processing in CAE Environment ......................................................................64

5.6. Data Preparation in RP Environment .......................................................................72

5.7. SLM Build Process ..................................................................................................74

5.8. SLM Post-Processing ..............................................................................................74

5.9. Iteration Steps .......................................................................................................75

5.10. Mold Validation .....................................................................................................76

5.11. NC-Form Grinding and Milling Machine Tool ..........................................................80

5.12. Grinding Tools for the Machining of SLM Workpieces .............................................81

5.13. Machine Tool Setup and Referencing of SLM Workpieces........................................81

5.14. Challenges by machining of SLM workpieces ..........................................................83

5.15. Grinding Parameters ..............................................................................................85

5.17. Results of the Machining Processes within Process Chain 3......................................91

5.18. Comparison between Machining Strategies ............................................................95

6. Appendix A – List of Features .....................................................................................97

6.1. Cavidade Fixa (P11) ................................................................................................97

6.3. Mandíbula (P14) ..................................................................................................102

1.1. Objective and Tasks of the Project

 to enhance the technological capabilities of SENAI and Brazilian Industry in the