extending tool coating life without oil and other .../media/files/autosteel/great... · temperature...
TRANSCRIPT
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.
Cell: 847-922-0381
Expanded White Paper available
Quick Start Consultation also available