Hybrid Additive Manufacturing

Hybrid Additive Manufacturing
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Hybrid Additive Manufacturing

Product catalog summary
Overview of Hybrid Additive Manufacturing
This document discusses the "Hybrid Additive Manufacturing" process, which integrates Selective Laser Melting (SLM) in a powder bed with high-speed three-axis milling. This hybrid approach allows for the interruption of the additive process to machine internal functional areas that are difficult to access later. This results in higher surface quality and precise reference surfaces for subsequent processes.

Materials and Applications
The process is applicable to various materials, including tool steel, stainless steel, nickel-chrome-iron alloys, titanium alloys, aluminum alloys, and cobalt-chrome steel. It is particularly beneficial in tool and mold making, rapid prototyping, and small series production, offering new design possibilities such as one-piece designs and complex internal structures.

Process Sequence
The process sequence involves repeated cycles of laser melting and milling. The document provides a detailed breakdown of the steps, including powder feeding, laser melting, pre-finishing, and finishing.

Milling Tools
The document details various milling tools used in the process, including solid carbide ball nose end mills and radius end mills. These tools are optimized for additive manufactured components, featuring high-performance coatings and special designs for efficient machining.

Machining Examples
Examples of machining parameters for different tools and materials are provided, illustrating the versatility and precision of the hybrid manufacturing process.

Contact Information
The document concludes with contact details for EMUGE-FRANKEN, a manufacturer of precision tools, and directs readers to their website for further information.
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Catalog excerpts

Hybrid Additive Manufacturing-1

Hybrid Additive Manufacturing Fraswerkzeuge fur additiv gefertigte Bauteile Milling Tools for Additive Manufactured Components

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Hybrid Additive Manufacturing-2

Hybrid Additive Manufacturing Das „Hybrid Additive Manufacturing“ ist ein additives Hybridverfahren, bei dem das selektive Laserschmelzen im Pulverbett mit DreiachsenHochgeschwindigkeitsfräsen kombiniert wird. Beide Verfahrenskomponenten finden dabei prozessintegriert auf einer Anlage statt. Der additive Aufbau der Bauteilgeometrie kann während des Prozesses zu bestimmten Zeitpunkten unterbrochen werden, um die spanende Bearbeitung von innenliegenden und nachträglich schwer zugänglichen Funktionsflächen zu ermöglichen. Dadurch lassen sich zum einen deutlich höhere Oberflächengüten erreichen,...

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Hybrid Additive Manufacturing-3

Prozessablauf · Process Sequence Pulverzuführung (Beschichten der Bauplattform) Powder feed (layer build-up on construction platform) Beschichter Layer build-up slide Absenken des Maschinentischs um Schichtdicke Lowering of machine tray by thickness of layer Laserschmelzen Laser melting Metallpulver (Pulverbett) Metal powder (powder bed) Selektiver Wärmeeintrag durch Laser Selective heat input by laser Sinter- und Bearbeitungstisch Sinter and machining tray Hochgeschwindigkeitsfräsen High-speed milling Laserschmelzen Laser melting Vorfräsen / Schruppen Pre-finishing / Roughing Laserschmelzen...

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Hybrid Additive Manufacturing-4

FRANKEN - Vorfraser fur additiv gefertigte Bauteile - Optimierte Querschneide - Spezielle Halsausfuhrung - Hochleistungs-Beschichtung Hartmetall-Kugelfraser ■ Solid Carbide Ball Nose End Mills - Pre-finishing end mill for additive manufactured components - Optimised chisel edge - Special neck designs - High performance coating HM Vorfraser Pre-finishing end mill schneidender Bereich cutting area of tool Optional Allround Beschichtung ■ Coating ALCR Kurze Ausfuhrung ■ Short design Bestell-Code ■ Order code Bearbeitungsbeispiel Material: Werkzeugstahl ahnlich 1.2709 Machining example Material:...

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Hybrid Additive Manufacturing-5

Hartmetall-Kugelfraser ■ Solid Carbide Ball Nose End Mills FRANKEN Fertigfraser fur additiv gefertigte Bauteile 2D-Bearbeitung von Hinterschnitten moglich Optimierte Querschneide Spezielle Halsausfuhrung Hochleistungs-Beschichtung - Finishing end mill for additive manufactured components - 2D machining of undercuts - Optimised chisel edge - Special neck designs - High performance coating HM Fertigfraser Finishing end mill schneidender Bereich cutting area of tool Allround ALCR Kurze Ausfuhrung ■ Short design Bestell-Code ■ Order code_ Bearbeitungsbeispiel Machining example Material: Werkzeugstahl...

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Hybrid Additive Manufacturing-6

FRANKEN Hartmetall-Schaftradiusfraser „Back Taper“ ■ Solid Carbide Radius End Mills “Back Taper” Hinterschnittbearbeitung Machining of undercuts - Fertigfraser fur additiv gefertigte Bauteile - 2D-Bearbeitung von Hinterschnitten moglich - T-Nutenform mit Radius - Hochleistungs-Beschichtung - Finishing end mill for additive manufactured components - 2D machining of undercuts - T-slot form with radius - High performance coating Bestell-Code ■ Order code_ Material: Werkzeugstahl ahnlich 1.2709 Machining example Material: Tool steel similar to 1.2709 Machining Tool Vorschlichten Pre-finishing Schlichten...

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Hybrid Additive Manufacturing-7

Anwendungen ■ Applications FRANKEN Stecker - Kern Plug - Core Prozesszeit Process time Stecker - Kavitat Plug - Cavity Prozesszeit Process time © Bildquellen: Image sources: • = Lagerwerkzeug, siehe Preisliste ■ Stock tool, see price list o = Kurzfristig lieferbar, Preis auf Anfrage ■ Available at short notice, price on request

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Hybrid Additive Manufacturing-8

- Multi-functional tool - Optimised chisel edge - Short shank lengths - Special neck designs - Multifunktionales Werkzeug - Optimierte Querschneide - Kurze Schaftlangen - Spezielle Halsausfuhrungen AllroundAllround Beschichtung ■ Coating ALCRALCR l3 = 5 x d1 - Kurze Ausfuhrung ■ Short design Bestell-Code ■ Order code l3 = 10 x d1 - Kurze Ausfuhrung ■ Short design 2772L Bestell-Code ■ Order code Bestell-Beispiel ■ Ordering example: 2781

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Hybrid Additive Manufacturing-9

FRANKEN A/f/cmo - Multifunktionales Werkzeug - Kurze Schaftlangen - Spezielle Halsausfuhrungen - Hochgenauer Eckenradius ■ Multi-functional tool - Short shank lengths - Special neck designs - High-precision corner radius Allround Allround Beschichtung ■ Coating ALCR l3 = 5 x d1 - Kurze Ausfuhrung ■ Short design Bestell-Code ■ Order code l3 = 10 x d1 - Kurze Ausfuhrung ■ Short design Bestell-Code • Order code • = Lagerwerkzeug, siehe Preisliste ■ Stock tool, see price list o = Kurzfristig lieferbar, Preis auf Anfrage ■ Available at short notice, price on request

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Hybrid Additive Manufacturing-10

FRANKEN Hartmetall-Schaftfraser „ENORM“ ■ Solid Carbide End Mills “ENORM” - Multifunktionales Hochleistungswerkzeug - Mit ENORM-Geometrie - Vibrationsarme Bearbeitung - Schneiden zur Mitte - Multi-functional, high performance tool - With ENORM geometry - Low-vibration machining - Centre cutting Allround Allround Beschichtung ■ Coating DIN 6527 - Kurze Ausfuhrung ■ Short design Bestell-Code ■ Order code DIN 6527 - Lange Ausfuhrung ■ Long design Bestell-Code ■ Order code Bestell-Beispiel ■ Ordering example: 1916A.003

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Hybrid Additive Manufacturing-11

Hartmetall-Schaftfraser „ENORM“ ■ Solid Carbide End Mills “ENORM” FRANKENi ■ - Multifunktionales Hochleistungswerkzeug - Mit ENORM-Geometrie - Vibrationsarme Bearbeitung - Schneiden zur Mitte - Multi-functional, high performance tool - With ENORM geometry - Low-vibration machining - Centre cutting Allround Beschichtung ■ Coating DIN 6527 - Lange Ausfuhrung ■ Long design Eckenradius ■ Corner radius Bestell-Code ■ Order code • = Lagerwerkzeug, siehe Preisliste ■ Stock tool, see price list o = Kurzfristig lieferbar, Preis auf Anfrage ■ Available at short notice, price on request

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Hybrid Additive Manufacturing-12

EMUGE-FRANKEN Vertriebspartner finden Sie auf www.emuge-franken.com/vertrieb EMUGE-FRANKEN sales partners, please see www.emuge-franken.com/sales EMUGE-Werk Richard Glimpel GmbH & Co. KG Nürnberger Straße 96-100 91207 Lauf GERMANY Frankenstraße 7/9a 90607 Rückersdorf GERMANY

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*Prices are pre-tax. They exclude delivery charges and customs duties and do not include additional charges for installation or activation options. Prices are indicative only and may vary by country, with changes to the cost of raw materials and exchange rates.