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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