Source: https://www.osapublishing.org/ome/abstract.cfm?uri=ome-4-8-1494
Timestamp: 2019-04-22 00:53:14+00:00

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We report for the first time use of 3D-printed metal extrusion dies for the extrusion of an optical material into an extrudate at elevated temperatures. Using lead-silicate glass as the material to be extruded, the 3D-printed dies demonstrated the same glass flow behavior as conventionally machined metal dies. Evaluation of the extrusion force at set temperature and extrusion speed revealed that the metal-type of the dies used did not affect the glass flow behavior. Using 3D-printed dies as delivered, the high surface roughness of the 3D-printed dies resulted in high preform surface roughness. However, this effect was overcome by finishing the easily accessible internal die surfaces over 1-2mm length upstream from the die exit. The opportunity of using 3D-printed dies offers unprecedented flexibility in the die design for unlimited tailoring of fluid flow within the die, which paves the way towards extruded items of arbitrary shape.
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Kumar, V. V. R. K.
Fig. 1 Schematics of die profiles in axial direction and of the glass flow direction for the two die designs used in this study.
Fig. 2 (a) Die constant calculated using the extrusion processing parameters and (b) cross-sectional area of the die welding chambers of the four extrusion trials considered here.
Fig. 3 Optical profiler images of 3D-printed Ti alloy die (a) media-blasted surface and (b) smoothed surface using conventional machining tool, and optical profiler image of (c) conventionally machined steel die surface. Details of die surface treatment are given in the text. The images have different vertical scale. The total range of the vertical scale is given as Δz. The average Sq values for the corresponding surfaces are also given.
Fig. 4 Optical profiler images of F2 glass preforms of extrusion trials A-E. The preforms were extruded through 3D-printed and conventionally machined dies. The images have different vertical scale. The total range of the vertical scale is given as Δz. The average Sq values for the corresponding surfaces are also given.
Fig. 5 Surface roughness Sq of (a) dies with different surface finish, and (b) preforms of the four extrusion trials considered here. Note the different Sq scale for the die and preform surfaces.
Table 1 Die design and metal type, ram speed v0, extrusion set temperature Tset, die temperature Tdie, log of the glass viscosity ηglass, ram force F, welding chamber cross section Achamber, and die constant Kdie calculated using the extrusion conditions for the four extrusion trials considered in this study.
Die design and metal type, ram speed v0, extrusion set temperature Tset, die temperature Tdie, log of the glass viscosity ηglass, ram force F, welding chamber cross section Achamber, and die constant Kdie calculated using the extrusion conditions for the four extrusion trials considered in this study.

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