Reducing the stair step effect of layer manufactured surfaces by ball burnishing

The layer technology enables fast and flexible additive manufacturing of forming tools. The disadvantages of this system is the formation of stair steps in the range of tool radii. Within this work a new method to smooth this stair steps by ball burnishing is introduced. This includes studies on the general feasibility of the process and the determination of the influence of the rolling parameters. The investigations are carried out experimentally and numerically. Ultimately, the gained knowledge is applied to finish a deep drawing tool which is manufactured by layer technology.