08 investigation of tooling durability for ahss
DESCRIPTION
ÂTRANSCRIPT
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Great Designs in Steel is Sponsored by:
ArcelorMittal Dofasco, ArcelorMittal USA, Nucor Corporation,
Severstal North America, Inc. and United States Steel Corporation
Investigation of Tooling Durability
for Advanced High-Strength Steel
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Darryl Young-Ford Motor Company
Tareena Mulholland-General Motors Corporation
Mike Klein-Chrysler LLC
T e a m M e m b e r s a n d
Contributors
• Datum Industries
• Competition Engineering
• Ion Bond
• Century-Sun
• MPD Welding
• Connie Yao
• Bohler-Uddeholm
• Dayton-Progress
• General Motors Corporation
• Ford Motor Company
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• MPD Welding
• ArcelorMittal USA
• Unisteel
• Rovalma
• Crucible
• Ford Motor Company
• Chrysler LLC
• Severstal North America, Inc.
• United States Steel Corporation
• Nucor Corporation
• ArcelorMittal Dofasco
S c o p e o f W o r k
• Simulate Production Process
• Progressive Die with Duplicate Operations
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• Flanging, Trimming, and Piercing
Part
• “Thing” – Not a
saleable part
• Uncoated DP980
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• Uncoated DP980
Material
Progression Strip
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Prc
& F
orm
Do
wn
Fo
rm B
ea
ds U
p
& S
tam
p I
D
Pie
rce
Tri
m
Pie
rce
Pie
rce
Tri
m
Idle
Fo
rm U
p 2
0 D
eg
Tri
m
Pie
rce
Fla
ng
e
Cu
t O
ff
Progressive Die
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Preliminary Results
• A Total of 62,000 hits Were Run
• Flange Steels Swapped Out When
Heavily Galled
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• Preliminary Results for Flanging are Available
• Mechanical Problems with Trim Station
Trimming
Initial Plan was to Evaluate Seven (7)
Die Materials/Coatings
• AISI-D2
• AISI_S7
• AISI-M4
• Uddeholm CALDIE™ with Plasma
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• Uddeholm CALDIE™ with Plasma
Nitride and PVD TiCN
• Nelson Associates Cast Cut® #1
• Crucible CPM 10V®
• Uddeholm VANADIS 4E®
S p e c ia l Le a r n in g
• Five Different Grades from Three Different
Manufacturers Chipped out or Plastically
Deformed.
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Deformed.
Spe c ia l Le a rning
Die Inspection
• Unbalanced Wear
Pattern on Pierce
Punches
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• Galling Observed on
Diagonally Opposite
Guide Pins and Bushing
Le s s o n Le a r n e d
• Dies Flex Elastically
– Die Needs Heals
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• Pin and Bushing Dies are Difficult to Open
– Die Needs Ball Bearing Guide Sleeves
Re-Designed Tool
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Flanging Tooling
Eleven (11) Die Material/Coatings were Evaluated
• AISI D2
• AISI D2 with CVD TIC
• Uddeholm Carmo® with Plasma Nitride and PVD CrN
• Uddeholm Vanadis 4E®
• AISI M2
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• AISI M2
• AISI M4
• AISI M4 with CVD TIC
• Uddeholm Vanadis 4E® with Micro-Plasma (HVOF-WC)
• AISI M4 with Hard Chrome
• AISI D2 with PVD AlTiN
• AISI M2 with PVD CrN
Audience Participation
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Audience Participation
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Flanging Results
– AISI D2
• Heavy Galling at 34,000 Hits
– AISI D2 with CVD TIC
• Good/Clean at 52,000 Hits
– Uddeholm Carmo® with Plasma Nitride and PVD-CrN
• Good/Clean at 52,000 Hits
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• Good/Clean at 52,000 Hits
– Uddeholm Vanadis 4E®
• Heavy Galling at 34,000 Hits
– AISI M2
• Heavy Galling at 18,000 Hits
– AISI M4
• Heavy Galling at 18,000 Hits
F l a n g i n g R e s u l t s
AISI M4 with CVD TIC
Good/Clean at 8000 hits
Uddeholm Vanadis 4E® with Micro-Plasma (HVOF-WC)
Heavy Galling Immediately
AISI M4 with Hard Chrome
Heavy Galling at 3000 Hits
AISI D2 with PVD AlTiN
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AISI D2 with PVD AlTiN
Galling Appearing at 8000 - 32000 Hits
AISI M2 with PVD CrN
Galling Appearing at 8000 Hits
P r e l im in a r y F la n g in g
Conclusions
• Un-Coated Tool Steels Fail
• Cool Coatings (Chrome, Micro Plasma) Fail
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• CVD or PVD Coatings are Necessary
• Plasma Nitriding Improves the Performance of
PVD Coatings
Pre limina ry Pie rc ing Results
• 62,000 hits accumulated on piercing
components to date
• Visual inspection of the pierce showed optimum
clearance between 10-15%
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clearance between 10-15%
– 15% and above showed increasing burr
– 5% showed a slightly pinched edge
O n g o in g Wo r k -Piercing
• Evaluate Materials and Clearance in Piercing
Operations
– AISI Grades A2, M2, M4
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– Clearances 5,10,15,20,25,30 %
– Burr Height Measurements
Ongoing Work-Trimming
• Accumulate More Hits– AISI D2
– AISI S7
– AISI M4
• New/Replacement
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• New/Replacement– CALDIE™ with Plasma Nitride and PVD-TiCN
– CALDIE™
– HWS®
– NAAMS G25HP
Ongoing Work -Flanging
• Accumulate More Hits
– AISI D2 with CVD-TiC
– Carmo with Plasma Nitride and PVD-CrN
• Evaluate Lower Cost Alternatives in Flanging
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• Evaluate Lower Cost Alternatives in Flanging
– NAAMS G3500 Gary Cast Iron
– NAAMS S0050A Cast Steel
– Tempered and Un-Tempered Condition
F u t u r e W o r k
• Evaluate More Material and Coating Combinations
– Flanging
– Trimming
– Piercing
• Production Correlation for Tool Life Prediction
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• Production Correlation for Tool Life Prediction
– Preventative Maintenance Schedules
– Less Expensive Materials for Shorter Runs
• Optimize Trim and Pierce Clearances
– Effect of Material Type and Gauge
Questions ?
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Great Designs in Steel is Sponsored by:
ArcelorMittal Dofasco, ArcelorMittal USA, Nucor Corporation,
Severstal North America, Inc. and United States Steel Corporation