Design criteria to use 3D printed polymeric tools in metal forming processes

In comparison to metallic tools used in forming processes, the 3D printed polymeric tools are significantly cost effectiveness, light weight and suitable for limited space production setups. However, owing to lesser material stiffness, polymer made tools cannot be used in all forming processes. Presently, there is no fixed criterion which defines the suitability of using 3D printed polymeric tools in metal forming processes. This research paper formulates a fundamental design criterion which identifies that whether polymeric tool will be able to successfully conduct a forming operation or otherwise. Keeping in view the ductile behaviour of 3D printed polymers before material yield, a design criterion based on von-Mises failure criterion is developed. A FE-simulation model is built and the simulation results are compared with practical results obtained from experimental setup consisting of pressure measurement sensors. The design criterion presented in this research paper will allow the manufacturers working in SME's (small and medium enterprises) to use low cost 3D printed forming tools in small scale production setups.