Experimental investigation of sheet metal forming using a recyclable low melting point alloy tool

Due to intense competition in automotive industry, new car models have to be launched as quickly as possible. A re-evaluation of the design and development phases has reshaped product development in order to get product earlier than competitors. Prototype production is one of the longest stages of product development due to physical verification activities. Shortening of this process will provide more opportunity to get project schedule earlier. Rapid prototype technologies are usually used as a guide for visual and packaging analysis. However, there is a requirement to use these parts for functional testing as well. Developing alternative rapid tooling methods which shorten the physical prototype production phase, while adequately supporting visual, packaging and functional aspects of sheet metal forming, can lead to considerable savings in vehicle prototype development. In this study, sheet metal prototype part using recyclable low melting point alloy was experimentally investigated by analysing dimensional conformance of tools and parts. In addition to wear performance, thickness reduction was investigated for stamped parts.