Research on the manufacturing process of tools with a L-PBF M300 steel working layer for sheet metal forming

The paper presents the results of research on the tool manufacturing process with a working layer obtained through 3D printing technology, using the L-PBF method, from M300 tool steel made on a steel substrate, intended for the plastic forming of sheet metal. In the first stage, model shapes were made using the L-PBF method, using various printing parameters, including laser power, distance between scanning lines, layer thickness, scanning speed and type. The shapes were tested for geometry, microstructure, phase analysis, texture, porosity, microhardness and wear resistance, coefficient of friction and surface roughness in contact with a selected range of sheets made of Ni, Fe and Al alloys. Additionally, the shapes were subjected to heat treatment and HIP, as well as laser burnishing and surface remelting. In the next stage, a plate with a threaded hole and threaded steel rolls were used, which were screwed into the plate, and layers of M300 steel with a thickness of 0.5-6 mm were made on their surface, using the L-PBF method, using selected, optimal 3D printing parameters. The obtained tool elements with working layers made of M300 steel were subjected to similar tests to those of the fittings. Then, comparative laboratory and industrial tests of sheet metal forming were performed using conventional tools and tools with layers obtained using the L-PBF method.