New Mold Steels: XPM and XPM VICTORY ESR - ++ …€¦ · · 2015-11-18New Mold Steels: XPM and...

XPM

The HighHard Plastic Mould Steel

…ready for use

Walter Grimm

1

New Mold Steels: XPM and XPM VICTORY ESR

Forged plastic mould steel blocks

ready for shipment at Gröditz´s

outdoor stock

19

XPM – High Hard Plastic Mould Steel



2

Daimler

BMW

VW

Ford

Faurecia

Plastal

Magna

Decoma

Plastic Omnium

Rehau

Peguform

Montaplast

Simoldes

Molders who authorized SWG mold steel:


2

Advantages of Schmiedewerke Gröditz:

• All steel is completely produced in the SWG factory in Germany

• Huge 60 MN forging press capacity for heavy blocks and big sizes

• ESR capacity up to 84MT/block, max. 1650 mm Dia.

• Heat-treatment facilities for homogenous mikrostructures

• Economically production


2


2

Advantages of Schmiedewerke Gröditz PM-Grades:

• production can cover whole range of sizes for PM industry

• kow-how for HighHard pre-hardend PM-steel up to 42HRC

• high homogeneity due to specific chemical composition

• huge ESR capacity for blocks up to 84 MT

• world wide distribution network

• specified by most leading molders and car producers


What is the difference between XPM and standard grade 2738 ?

reduction of carbon content for a more intensive heat treatment

lower Si, Mn and Cr for the reduction of segregation and a better homogenity

alloying of Mo and V for a better through hardening and higher tempering temperature

9

SWG Grade C Mn Cr Mo Ni others

2738 0,38 1,50 2,00 0,20 1,00 +

XPM 0,27 1,50 1,50 0,55 1,00 +


2

Concept of Schmiedewerke Gröditz on pre-hardened Plastic Mould Grades

for Korean Market:

SWG Grade Machin-

ability

Polish-

ability

Grain-

ability

Wear-

resistance

Weld-

ability

Tigermould +++ + + + ++

2738eco +++ ++ ++ ++ ++

2738 ++ ++ ++ ++ ++

XPM ++ +++ +++ +++ ++++

XPM-ESR ++ ++++ ++++ +++ ++++


2

What is XPM ?

advanced pre-hardened high hard mold steel

38 – 42 HRC


2

What is XPM ?

highly improved mold steel

based on German standard grade 2738


2

What is different between XPM and 2738 ?

higher hardness: 40 HRC / 31 HRC

much lower segregation rate (homogene composition of the block): - 50%

significant better homogenity and pure micro structure

through hardenability up to extrem sizes: up to 1500 mm

better machinability

better grainability

better polishability

better weldability

higher thermal conductivity: + 20%


What is the demand on a new pre-hardened plastic mould steel ?

a growing need for moulds with larger dimensions

a steady increase in hardness of pre-hardened steels

increasing demands in terms of surface finish quality of moulds

continuing requirement for ease machining

Standard plastic mould steel grade 2738 is not able to meet all these requirements !

2

1953 1976 1985 1995 2006 1959 1967

Tendency in car design:

growing size of bumpers

Example:

Mercedes Benz E-Class

front end bumper

Concequence:

steadily bigger moulds

and steel blocks

Steel bumpers

Plastic bumpers


3

2009

What is the difference between XPM and steel 2738 ?

reduction of segregation in steel blocks due to special composition

leads to a significant homogenous and pure structure


2738 XPM

10


What is advantage for the mould maker ?

Better homogenity and high hard structure of XPM

guarantees outstanding etch grain and mirror finish reliability

XPM: Etch grain reliability

XPM: mirror finish reliability

Application of XPM Steel:

Grade is specified by

BMW and Mercedes Benz for all

etch grained interior plastic parts


6


Dipl.Ing. Walter Grimm

XPM High Hard for exterior parts of

Daimler Benz plastic car:

„Smart Rodster“

XPM High Hard grade for mirror finish

polished mould surfaces

Application: Moulds for lighting systems


7


Dipl.Ing. Walter Grimm

Production of extremly heavy blocks

and forgings

e.g. cavities for large bumper moulds

- no significant hardness loss in core

Hardness about cross-section

XPM36, size: 1250x505mm²

quenched and tempered to 36-40 HRC

30

32

34

36

38

40

42

44

0 50 100 150 200 250 300 350 400 450 500

distance to surface (mm)

ha

rd

ne

ss

(H

RC

)

H/2


XPM project:

35 tons bumper mould block:

Porsche Sports Limousine „Panamera“


What is the advantage for the mold maker with XPM ?

significant easier machining in comparison to steel 2738 at same hardness

faster machining

extended cutting tool life

higher productivity of mould shop

100 200 400 600 800 1000

Tool life distance (m)

0

50

100

150

200

250

To

ol

we

ar

VB

(m

y)

XPM

2738

3 axis machine

Operation: Finish millingVc 300 m/min.

Constant parameters:

Ae = 0,3 mm

Ap = 0,2 mm

Fz = 0,3 mm

L/D = 10,3

Toricall cutter dia. 15 mm, Carbide rev. Tips, TiAlN coated,

3-axis machining, planetary milling

Finish milling, Vc = 300 m/min


Machining parameter

2738 via XPM


What is the advantage for the mould maker (in comparison to steel 2738) ?

weldability is significantly improved due to lower C-equivalent

less sensivity to welding cracks when welding without preheating

easy repair welding operation possible

recommendation for TIG Filler: Cronitex 130 ST

Welding parameters:

Preheating: 380 C

Filler: Cronitex 130 ST

Lowest temp. 150 C

Stress relief anneaning: 560°C

14


14

SWG Grade 20 – 100°C 20 – 200°C

20 – 300°C

Tigermould 35,7 33,4 32,0

2738 35,7 33,2 31,9

XPM 37,2 41,0 39,2

Thermal Conductivity in W/mK


What is the advantage for the molder (in comparison to steel 2738) ?

the thermal conductivity of XPM grade is approx. 20% higher than 2738

therefore the cooling rate of the mould steel is approx. 20% higher

this makes up to 10 % faster production cycles possible at injection molding

clear productivity benefits due to better thermal conductivity of XPM

up to 10 % higher production

Faster solidification of the plastic

in the bumper mould

15


What is XPM VICTORY ESR ?

Electro Slag Remelted

high pure XPM VICTORY mold steel

- designed for mirror finish polishing -


What is different between XPM and XPM VICTORY ESR ?

higher cleanliness due to ESR metallurgy:

DIN 50602: K1 10 or ASTM E45- Method A with type A 0,5 ; B; C and D each 1

extrem low segregation rate due to ESR metallurgy: -80%

guaranty for mirror finish polishing: > grain 1000; ISO Standard N-0, Ra: < 0,10 my


Electric Arc Melting

Ingot Casting

Electric Slag Remelting (ESR)

SuperClean Technology


Lower degree of segregation

Higher degree of cleanliness (better high gloss polishability)

Homogenous and even microstructure

Improved technological properties

Adjustment of mechanical properities in longitudinal and

transvers direction (isotropical steel)

ESR ingot after remelting


What is the area of application for XPM VICTORY ESR ?

High gloss polished plastic molds

Plastic molds for hard chrome plating

Car light molds


high-polishablehigh-polishable

polishablepolishable

limited polishabilitylimited polishability

20 30 40 50 6050

60

70

80

90

100

Hardness in HRC

Polishability in %

800 HV0,05 2000 HV

he

at

tre

ate

d s

tee

ls

ha

rden

ing s

tee

ls

ste

els

with

surf

ace

tre

atm

en

t

500 x 50 x

Conventional melted steel: hard non-metalic inclusions effection polishablility

Solution: ESR melting = VICTORY grades


Application of XPM VICTORY ESR:

Molds for

Rear View Mirror

Chromium Plated Plastic Parts


Xenon Head Light Mercedes E-Class

LED Rear Lamp Audi A1

Full LED Head Light Audi A8

LED Rear Lamp VW Golf VI

Application of XPM VICTORY ESR: Car Light Systems


Recent car lighting projects with SWG mold steel:

BMW F10 LCI

VW Jetta A06 – 8 tools

Mercedes W207/212

Porsche Panamera

Opel Insignia

Nissan X11M

Saab 540

VW Gol – SOP 2012

Citroën Picasso

Skoda Octavia

Nissan X11 04/2011


Steel Grade

Schmiedewerke

Gröditz

Delivery

Condition

Application Production Steps

XPM Q+T: 38 – 42 HRC Car light molds

“non decorative

parts”

1) finish machining

2343 VICTORY ESR EFS annealed Car light molds

“decorative

parts”

1) pre-machining

2) vacuum hardening ~ 50 HRC

3) finish machining

New:

XPM VICTORY ESR

Q+T: 38 – 42 HRC Car light molds

“decorative

parts”

1) finish machining

2083 VICTORY ESR

annealed

Car light molds,

corrosive plastics

“decorative

parts”

1) pre-machining

2) vacuum hardening ~ 50 HRC

3) finish machining

European material concept for car light systems

Total demand: ca. 55% 2343ESR (XPM VICTORY ESR), 40% XPM, 5% 2083ESR


Comparison of 2343 VICTORY ESR and XPM VICTORY ESR

Chemical composition in %

Grade C Si Mn S Cr Ni Mo V

2343

VICTORY

ESR

0,38

1,00

0,40

0,002

5,20

-

1,30

0,40

XPM

VICTORY

ESR

0,26

0,20

1,45

0,002

1,25

1,00

0,50

0,10


Comparison of mold making:

2343 VICTORY ESR via XPM VICTORY ESR

pre-machining hardening finish machining polishing

finish machining polishing

Conventional concept 2343 VICTORY ESR

New concept XPM VICTORY ESR


Thank you very much for attention!

Date post:	28-Apr-2018
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New Mold Steels: XPM and XPM VICTORY ESR - ++ …€¦ · · 2015-11-18New Mold Steels: XPM and...

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