The future mobility industry is increasingly utilizing advanced tools for cutting and machining lightweight parts to enhance the fuel efficiency of automotive engines. Machining companies are turning to polycrystalline diamond (PCD) tools to boost productivity in the production of these lightweight components. PCD tools provide exceptional machining performance and a long service life, making them ideal for high-mix, low-volume production, which often involves customized requirements for various materials. To further improve efficiency, this study explores the application of metal 3D printing technology in the manufacturing of PCD tools. This technology allows for the creation of PCD tools with superior cutting performance and wear resistance, tailored for high-speed machining of lightweight materials, including complex shapes. Thus, research into this area is essential. In this study, we manufactured boring tools by brazing PCD tips onto three different laminated structures created using Fused Deposition Modeling (FDM), a method within metal 3D printing technologies. We then evaluated the fabricated boring tools through comparative machining experiments against existing sintered PCD boring tools. The results indicated that the 3D-printed solid tools demonstrated no significant differences in machining accuracy or surface quality compared to the conventional tools.

This research developed a CAM S/W, which generates an adaptive 5-axis tool path, to optimize the quality of Direct Energy Deposition (DED) 3D printing. After reconstructing part shapes and generating printing paths in each shape, the path simulation including automatic collision detection was implemented. Productivity and printing quality were improved through equipment improvement and process optimization. In addition, high-quality parts with desirable physical and mechanical properties were produced by generating an adaptive 5-axis path specialized in the printing process that reflects various physical phenomena and monitoring results. Finally, the performance of CAM S/W was verified through the production of prototypes for industrial components.

Chiefly, the metal wire-feed and laser additive manufacturing (AM) is a deposition process to produce larger mechanical parts required for aerospace, shipbuilding, automobile, and mold repair industries. The principal advantage of metal wire-feed AM is the high deposition rate compared to an assisted metal powder-feed AM, and metal powder-based fusion AM. During the wire-feed deposition process, the feed orientation is a critical parameter managed at all stages of processing. A better surface finish is attained when the melted wire flows smoothly through the process, and a wire feed direction that is utilized opposite to the deposition direction yields the best results. To improve the surface quality of metal 3D printing, we designed a rotating wire feeder, the feed direction of which varies with the direction of deposition; all free-form lines which thus exhibit identical surface qualities. Here, we use a rotating stage to orient the wire-feed direction according to the bead direction, a slip ring to supply electrical power to the feeder motor, and utilized two rotating channels on a plate to supply Ar gas and extract fumes safely during the processing stage. We evaluated the rotating wire feeder by building various parts as needed to the equipment.