The development of tool components is based on two different sections. On the one hand a plunger is developed which is responsible for the pressure translation within the high-speed forming process. Within the HGU a short-term but very strong electromagnetic field is generated that accelerates the plunger. The acceleration takes place in the direction of the workpiece and the plunger strikes on a forming medium which generates a pulsed pressure state. This pressure ensures that the sheet metal is formed in the die. The plunger must have a very high conductivity with high strength and low mass at the same time. For this purpose, two concepts are made with of titanium (TiAl6V4) and aluminum (AlSi10Mg) in Selective Laser Melting (SLM) process. The manufactured components could be successfully used in the HGU. It was possible to achieve a weight saving of over 50 % compared to a conventionally produced component (turning, milling). The weight savings could be achieved by consistent lightweight design which was realized by topology optimization.
The other research focus is on an additively manufactured die through FDM. The aim of this process is to produce thermoplastic dies which satisfy the mechanical loads of the HGU process. The big advantage of complex component design trough AM should be exploited in this project to produce innovative rupture discs in the considered forming process. For this purpose, the materials Polycarbonate (PC) and Ultem 9085 (blend of PEI and PC) were investigated, since both materials offer good mechanical properties with regard to the compressive strength. Another aim for the material selection is the achievable layer thickness in the FDM process. PC can be processed with a minimum layer thickness of 0.127 mm (Ultem 9085 only with 0.254 mm), which leads to a higher geometrical accuracy and better surface finish without post-processing. Another process characteristic is to be used for the forming process: the porosity of the FDM structure. The idea is to use the porosity for venting the forming process. The filament deposition and the layer-by-layer principle lead to process-related porosity in the structure (see Figure 2).