Methodology for embedding mineral insulated cables into DIN 1.2311 tool steel for the manufacture of smart tooling

Abstract

In the present climate led by industry and digital manufacturing, the implementation of intelligent tooling in manufacturing processes has become imperative. In the case of metal forming processes, this requirement is translated into controlling the material flow and the temperature in the tool-part contact interface. In this manner, not only the mechanical properties of the produced parts are predicted, but also the status of the tooling can be monitored. To that end, a methodology for embedding sensors close to key areas needs to be developed. Additive Manufacturing holds a great potential for enabling such integration. However, high process temperatures inherent to metal AM processes are a limiting factor in this matter. With the aim of taking a step forward in this field, in the present work a methodology for embedding mineral insulated cables into metal forming tooling has been developed. Furthermore, the minimum cable size integrable by means of this technology has been determined and the main limitations of this process exposed. It has been concluded that low energy inputs are necessary to avoid the destruction of the sensorial components and that adaptive process parameters are necessary if sound metal coatings over undamaged components are to be deposited.