extending tool coating life without oil and other .../media/files/autosteel/great... · temperature...

Extending Tool Coating Life

Without Oil and other Conventional Fixes

UHSS Higher Deformation Temperatures

Demand New Solutions

W. Jeff Jeffery

CEO - IRMCO

Stamping Lubricants.

Redefined

I Believe There is a Better Way

Joint Development Project

GE R&D – Louisville, KY

Bennett Tool – Nashville, TN

IRMCO – Evanston, IL

Almost 2X Forming Force Required

Additional

energy

needed

for AHSS

+ Higher required tonnage/force

+ AHSS higher yield stress

+ Work hardening component

= Higher metal flow stress

= Higher deformation temps

= Higher tool wear and abrasion

Newton’s 3rd Law

“For every action, there is an equal and opposite reaction.”

Energy In = Energy Out. As metal is formed, the crystal structure is forced to

microscopically slide or “grind” internally. The friction between the moving crystals

causes heat. As the metal is deformed, it heats up and causes a change in strength

that results in a chain reaction of more deformation and more heat in the

surrounding metal.

Kinetic Energy. Is the energy that an object (press ram) possesses due to its

motion. It is the energy needed to accelerate a body of a given mass from rest to its

stated velocity. Having gained this energy during its acceleration, the body

maintains this kinetic energy until its speed changes when the ram or punch strikes

a die and forms the sheet metal.

This Energy is transferred or stored for a period

in the sheet metal and/or tool as Heat.

Dual Phase 980

97.1 °C = 206.78 °F

Source: Taylan Altan CPF

25 mm stroke

DP 980 – worked harder

219.8 °C = 427.64 °F

55 mm stroke

Source: Taylan Altan CPF

Heat Checking of Tools

Micro-Welds = Adhesive Wear

Pull-out

Tool Work material

Micro-welds

Shear Fracture = Wear

Source: Bohler Uddeholm

Galling

Small pieces of work

material adhere to the

tool surface

Tool

Source: Bohler Uddeholm

What’s the Fix?

More Lube?

Extreme Pressure Agents

Heat Capacity = Heat Absorption

Heat capacity (or thermal capacity) is the ratio of the heat

added to (or subtracted from) an object to the resulting

temperature change.

Water btu/lbm-F = 1.0

Oil btu/lbm-F = 0.4

Oil can only absorb 40% of the energy that water can

A 4:1 mix of oil is still 20% oil

You lose 12% of the energy sink compared to water

No matter how much you flood the tool

lbm = pounds-mass

ETHSP - Extreme Temperature High Solids Polymer

Forward Looking Infrared -FLIR Cameras

CPF/EWI Deep Draw Test

30 tons

BHF

&

70 tons

BHF Source: Taylan Altan CPF & Hyunok Kim, EWI

Force vs. Stroke@ 70 tons/BHF

Source: Taylan Altan CPF & Hyunok Kim, EWI

Comparison of Flange Perimeter

Lube A & B both

scored better at 2X+

BHF tons than the

rest of the field

Source: Taylan Altan CPF & Hyunok Kim, EWI

300% increase in coating life

Test Tool

8 Thermocouples

4 data collection points in draw ring

Will measure live metal deformation

temperatures

4 data collection points in blank holder

Will measure sliding friction temperatures

Aida 330 Ton Servo Press

Test Press is Blank fed

Servo action will allow

variation in ram speed

Will also permit rapid

multiple “pecking” strokes

Data collection of both

tonnage/force and

temperature will clarify

impact of stroke variations

Friction – Friend or Foe?

“Jujitsu” where the knowledge of anatomy and

the principle of leverage are applied so that the

strength and weight of an opponent are used

against him.

jjeffery@irmco.com

Cell: 847-922-0381

Expanded White Paper available

Quick Start Consultation also available