VBN Components AB 3D-printing for demanding applications ESS, Max IV, IUC Syd/Big Science Dk Lund, 2017-09-19 Ulrik Beste CTO, VBN Componens AB ulrik.beste@vbncomponents.com 070 235 86 26
VBN Components AB Materials development for Additive Manufacturing Founded 2009 by Vikner_Beste_Nilsson Business development in Uppsala Innovation Centre, UIC (World s 10th best business incubator) R&D work performed at Ångström Laboratory, Uppsala University Winner of the largest innovation price in Sweden 2013: The SKAPA Development Award in the memory of Alfred Nobel. Production capacity in Uppsala, Sweden --------------------------------------> Materials science Powders Additive Manufacturing Tribology
VBN Components focus To develop NEW MATERIALS and PROCESSES for suitable 3D-printing method. The materials (Vibenite ) are always wear resistant with good tribological properties. Manufacturing of Vibenite where customer sends a CADdrawing and gets: A) hardened near-net-shape blanks or B) finished component (by grinding or edm) Three different materials today: Vibenite 280 wear applications, cutting tools Vibenite 150 functional prototypes, tools, etc Vibenite 350 wear resistant and stainless for plastic processing tools, wear parts, pumps, rings, valves. etc Max size: 200 x 200 x approx 350mm (today).
Example, gear cutting hob
Vibenite and other AM materials Vibenite materials in its own hardness region compared to other materials.
VBN materials development Toughness Shaper cutter in Vibenite 280 Optimum 70 VBN alloys tomorrow VBN alloys today Existing traditional alloys (not only AM materials) Hardness
Why 3D-printing of Vibenite? Traditional manufacturing Material Machining Powder HIP Heating Forging Rolling Annealing Oxide scale removal Hot rolling Tempering Drawing Straightening Grinding Cutting Turning Milling Heat treatment Grinding + a lot of smaller operations + a lot of stop times + a lot of intermediate storages = Finished component VBN Components manufacturing Powder 3D-printing Heat treatment Grinding = Finished component
Which customer problems can be solved by VBN? Higher performance Benefits in production Benefits in components Benefits for the planet Wear resistant materials (70+ HRC) with well dispersed fine carbides No soft machining (drilling, milling, turning) Complex shapes for modulus systems Heavily reduced environmental impact Intelligent geometries Minimized material stock Small or large series Less material consumption Cutting media channels No cutting chip handling Spare parts Less transport of heavy products Lightweight structures (lower handling damages) Minimized cutting fluid handling Cooling channels More uniform hardening
VBN business model Manufacturing cost Traditional manufacturing cost for extremely wear resistant materials difficult to machine VBN s market today Traditional manufacturing cost VBN s market tomorrow AM cost today AM cost tomorrow Component complexity
Vibenite 280 High strength, high hardness and very high wear resistance. Fine microstructure with high volume of fine carbides -> high toughness High hot hardness and uniformity. Wear parts and Cutting tools such as gear hobs, broaches, cutters, etc. Microstructure (hardened at 1180 C) Fe C Cr Mo W Co V Bal. 2,30 4,2 7,0 6,5 10,5 6,5 Composition
Hardness (HRC) Vibenite 150 High performance wear resistant Multi- Purpose material. Hardness 55-64 HRC. Fine microstructure with fine and wear resistant carbides -> unique combination of toughness and wear resistance. Functional prototypes, tool holders, cold work applications C Cr Mo W V Fe 1.5 4.0 2.5 2.5 4.0 Bal Composition 66 64 62 60 58 56 54 52 950 1000 1050 1100 1180 Hardening temp ( C)
Vibenite 350 Very wear resistant and stainless material. ~60 HRC. Choose this extreme stainless material, without need for machining. Fine microstructure with fine carbides in a chromium rich martensitic stainless matrix -> excellent properties. The material has been developed with support from Swedish Energy Agency -> large energy and material savings. Applications: Valves, pumps, turbines, marine applications, plastic processing tools, etc. C Cr Mo V Fe 1.9 20 1.0 4.0 Bal Composition
Gear cutting tools at Volvo ( hobs ) Life Cycle Cost-calculations on Vibenite 280-tools (Uppsala University) Analysed scenarios at Volvo CE: Standard: Standard gear hob with cutting fluid Vibenite 1: Vibenite 280 Optimum 70 - with 2,2x life time Vibenite 2: Vibenite 280 Optimum 70 - with 2,0x life time and half cycle time (double feed)
Gear cutting tools at Volvo Heavy reduction of cost per manufactured gear at Volvo CE 1,2 1 0,8 Standard Vibenite 1 Vibenite 2 0,6 0,4 0,2 0 Verified in real tests!
Heavy material saves on gear hobs Yield traditional manufacturing Yield VBN Additive Manufacturing Manufacturing of steel bar ~70% - Manufacturing of hob blank ~50% ~98% Total material yield manufacturing ~35% ~98% Traditional manufacturing Yield manufacturing 35% 98% Performance (feed) 100% 200% Weight hob 15.3 kg 11.2 kg Number of produced gear/gear hob 7150 st. 14300 st. Hob material consumption per produced gear HMCPPG* VBN Additive manufacturing 6,1 g 0,80 g The first grinding removes more material for the 3D-printed part, but the following grindings are the same. The material savings on coatings are not included. The traditional example also needs a bar in close dimension, which is not always the case.
Low weight gear hobs saves energy and spines Weight save: 11,2kg instead of 15,3kg Approx 15 reconditions / hob Each reconditions needs approx 18 lifts Saved lifted weight on one hob: 1107 kg In addition, the risk for handling damages is reduced. (Handling damages is the most common fault on gear hobs.)