Simulation-based tool development for the mechanical production of wear-resistant surfaces in tool and mold making (SimMillDesign)

Tools used in forming technology or injection molding must meet special requirements with regard to their surfaces. In use, they are subject to high mechanical loads and in some cases high temperatures. In addition, the friction between the tool and the workpiece must be minimized and the resistance of the tools maximized in order to achieve good workpiece quality and high wear resistance. Residual compressive stresses in the surface-near edge zone can improve the resistance of the forming tools. This can suppress the formation of cracks that lead to stress concentrations, chipping and corrosive attack. This is rarely possible with conventional manufacturing of these workpieces. In order to achieve smooth, residual stress convex surfaces in automatable, machine processes, the SimMillDesign project aims to further develop and qualify milling tools and processes with the aid of chip shape simulations.