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New Trends in Processing and Application of Tool Steels for Cold Forming
- Tool Steels, Heat Treatment, Application Examples Peru Nov. 2007

Dipl.-Wirt. Ing. Andreas Hunger

Drrenberg Edelstahl GmbH Engelskirchen Germany

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Content
1. 2. 3. 4. 5. 6. Introduction Requirements on tool steels Tool steels and factors of influece on micostructure Effect of heat treatment on properties of cold work steels Application examples Conclusion

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Example of use high strength materials shown at the BMW 5th series
Percentage of high strengths materials [%] E60 60 E39

5th series BMW (E60) Aluminium Standard sheets High strengths sheets (Rm > 320MPa) 15% 62% 23%

40

20 E28 1980 1985

E34

1990

1995

2000

2005

Quelle: BMW AG

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Load of punching tools using different sheet materials

Punching : Clearens: Cutting edge: Oval-Punch (8x16mm) 10 % 20 small radius
15

ZStE180 TRIP700

Cutting force [kN]

ZStE180 Tensile strength: Cutting force:

332 MPa 5,16 kN

10

TRIP 700 Tensile strength: Cutting force:

~850 MPa 17,62 kN

-5 0 0,2 0,4 0,6 0,8 1

Cutting way [mm]

Quelle: IFU-Stuttgart

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Typical wear of sheet-metal forming tools

adhesive wear abrasive wear

separation of adhesive junctions

ploughing

cutting

cracking

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Requirements on cold work steels

required properties for use:
high compressive strength high hardness high tensile strength sufficient toughness to avoid brittle spontaneous fracture and increase fatigue life high resistance against abrasive wear low adhesion properties (transfer of material)

required properties for production:

good castability good formability good machinability good hardenability good dimensional stability

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Structure comparison 1.2080/D3 - 1.2379/D2 - CP4M - CPOH - WP7V

1.2080/D3 2,0% C 12,0% Cr

1.2379/D2 1,6% C 12,0% Cr

CPOH 1,0% C 8,0% Cr

CP4M 0,6% C 5,0% Cr

WP7V 0,5% C 7,8% Cr

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Hardness of different carbides

3500 3000 Hardness [HV 0,05] 2500 2000 1500 1000 500 0 Element Type Scatter value

Ti MC

V MC

Nb MC

W MC

Mo M6C

Cr M7C3

Fe M3C

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2009-8

Properties and classification of cold work steels

tough hard rich in carbides

wear resistance

toughness

wear resistance

42

46

50 54 58 hardness in HRc

62

66

toughness

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2010-8

Cold work tool steels

material C standard chemical composition Si Mn Cr Mo V W Ni 4,00 1.2842 1.2363 CPOH 1.2767 1.2550 WP7V tempering behaviour

0,45 0,45 0,30 1,40 0,20 0,60 0,70 0,30 1,00 -

0,20 2,00 -

0,50 0,30 0,30 7,80 1,50 1,50 0,90 0,30 2,00 0,40 0,15

1,00 0,30 0,60 5,00 1,00 0,30 1,00 1,10 0,30 8,00 2,50 0,30

+ add.

1,20 0,30 0,30 12,0 1,40 1,70 2,50 1,55 0,25 0,30 12,0 0,80 1,00 2,10 0,25 0,30 12,0 0,80

CPR 1.2379 1.2436

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Micro structure of cold work tool steels from different production methods

Cast D2 / 1.2382

Forged D2 / 1.2379

Powder metallurgy D2 / PM 1.2379

50m

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Structure of a cast ingot

Ingot center segregation

Ingot mould

Ingot

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Crack propagation in steels with distributed or connected carbides

crack

distributed carbides

carbide network

Berns et al.

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Influence of carbide structure on the toughness of a steel

Toughness

Carbide amount

Toughness

Carbide size

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Atomising plant

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Hot isostatic pressing

Illustration of production steps for hip-process
Argon under pressure

vacuum pump

gas atomised powder

filling capsules

evacuating and welding of capsules

HIP-cycle

Removing the capsule

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2091-8.0

Comparison conventional - powder metallurgical

1.3344 1,30 4,20 6,40 5,00 3,10 rest C Cr W Mo V Fe PMD 23

64 HRc hardness 64 HRc charpy notch (ISO-U) impact value 14 J 43 J 3585 MPa bend fracture strength 5350 MPa 9,8 7,2 grinding ratio

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Impact Toughness: Standard- compared to PLUS-material

25

20

60 HRc

58 HRc

Impact values in J

15

10

0 1.2379 Standard (transve rsal)

1.2379 conventionell: s pecimen taken f r om 70mm at 1/ 4 D 1.2379 P lus : s pecimen taken f r om 207mm, cor e All s amples unnotched All s amples har dened at 1050 C and s econdar y temper ed

1.2379 Standard (longitudinal)

1.2379 Plus (transve rsal)

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2009-8

Properties and classification of conventional cold work tool steels

tough
PM Ma ter

hard

rich in carbides

Wear resistance

toughness

wear resistance

42

46

50 54 58 Hardness in HRc

62

66

Toughness

ial

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Drrenberg Edelstahl PM-Tool Steels

C 1.3343PLUS PMD 23 PMD M4 PMD 30 PMD T15 CPOHPLUS 1.2379PLUS PMD V4 PMD 9 PMD 10 PMD440 0,90 1,30 1,35 1,30 1,60 1,00 1.55 1,50 1,80 2,45 2,20 Cr 4,00 4,20 4,20 4,20 4,20 8,00 12,00 8,00 5,25 5,25 17,50 W 6,40 6,40 5,80 6,40 12,20 2,50 0,80 1,50 1,30 1,20 0,50 Mo 5,0 5,00 4,50 5,00 V 1,90 3,10 4,00 3,10 5,00 0,30 0,90 4,00 9,00 9,75 5,80 MartensiticStainless steel Coldworksteels 8,00 5,00 Highspeedsteels Co

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Drrenberg Edelstahl PM-Tool Steels

grade
CPOHPLUS 1.2379PLUS PMD V4 PMD 10 PMD 440 1.3343PLUS PMD 23 PMD M4 PMD 30 PMD 52

properties
very tough cold work steel standard cold work steel wear resistant cold work steel, increeased V-content, good toughness exeptionally high wear resistant cold work steel, with high V-content stainless including carbides, food processing, plastic processing standard HSS flat, standard dies, EDM-blocks, (M2) standard HSS round, standard dies, chipping standard HSS flat, sheet metal forming, fine blanking, cold forming HSS with good thermal stability, for cold forging, chipping HSS with good thermal stability, improved wear resistance, for chipping and cold forging

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1948-4

Advantages of powder metallurgical tool steels

good machinability good grindability good polishability high degree of purity high toughness high compressive strength high wear resistance structure with less segregations isotropic change in dimension

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Principles of tempering behaviour

+ Cr, Mo, V, W

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Advantages of secondary hardenable steels

Due to the high tempering temperatures these materials are most suited for the following processes: PVD-coating CVD-coating Nitriding EDM Grinding The typical properties are: High toughness and high hardness Dimensional adjustments possible

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Heat treatment process

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1979-8.0

Influence of tempering on micro structure and mechanical properties (grade DE - CPR)

annealed 25 HRc

hardened 58 HRc impact value:

1 x tempered 61 HRc 11 J

2 x tempered 63 HRc 13 J

3 x tempered 63 HRc 28 J

40 m

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Influence of the heat treatment of the carbide structure (material: PMD M4 / 62 HRc)

20 m

20 m

Globular carbide structure Optimized heat treatment

Coagulation of carbides Long austenitizing time

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Example for the use of PM- tool steel

Application: Dimensions: Material : Hardness: Life Time: Cause for the Failure: pressing tool for brake lining production 160 x 100 x 105 mm 1.2379 plasma nitrided Nht.~0,1mm 57,5 HRC ~ 20.000 pieces massive abrasive wear, evoked by hard powder particles Changing material to high wear resitant special steel PMD 10 ~62HRC
Quelle:

Solution:

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Example for the use of PM tool steel

use: material: hardness: problem: forming die 1.3343 62,0 - 62,5 HRC insufficient toughness, crack propagation along the carbides

solution:

material change to PMD M4 with ca. 62 HRC

10 mm

500 m

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Example of use: Coining punches

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Example for the use of PM tool steel

Use: Material: Hardness: Coining punch 1.2379 59,5 - 60,0 HRC

Reason for failure: Low toughness and compressive strength Material change to PMD M4 (62 1 HRC)
20 mm

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2759-9

Example for the use of PM tool steel

Use: Material: Hardness: Perforating knife 1.2067
2 mm

63,5 HRC

Reason for failure: Cracking in the cutting tees, less toughness Material change to PMD23 (64 1 HRC)
20 mm

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Example for the use of PM tool steel

Use: Material: Hardness: Cutting punch 1.2379 62,5 - 63,0 HRC
50 m

Reason for failure: Less toughness Changing material to PMD30 (63 64 HRC)
10 mm

40 mm

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Comparison of lifetime 1.2379 PMD23

Working area Tool Production way dimensions Sheet material Lifetime: 1.2379 / 59 HRc PMD23 / 61 HRc Cold work Precision blanking Wire cutting 142 x 76 mm
50 mm

16MnCr5, ~600 MPa, 5 mm, bright ~20.000 pieces >60.000 pieces

100.000 80.000 60.000 40.000 20.000 0 1.2379 PMD23

Number of pieces

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Comparison of lifetime 1.3343 PMD10

Working area Tool Production way dimensions Sheet material Cold work Blanking tool (high speed blanking) Wire cutting ca. 13,5 4 mm Cupper, ca. 680 MPa, 0,2 mm, bright
Number of pieces 150.000 100.000 50.000 0 1.3343 PMD10
30 mm

Life time: 1.3343 / 63 HRc 400.000 pieces PMD10 / 63 HRc >1.200.000 pieces

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Economic calculation
Type of Tool: Precision blanking punch Result: B: Number of regrindings C: Total parts per tool (A x B) Economy D: Production cost of the tools E: Cost of the tool material F: Total tool cost (D + E) G: Cost for the regrinding including changing tools H: Total cost of regrinding and changing tools (B x G) I: Total tool cost until failure (F + H) J: Tool cost per punched part (I : C) K: Economic advantage [%] Material: 16MnCr5 Tensile Strength: ~ 600 N/mm Thickness: 8,0 mm 1.2379; 59 HRc 2.000 3 6.000 390,-10,-400,-270,-810,-1.210,-0,202 Parts per Month: 12.000/Month PMD M4; 61 HRc 8.000 10 80.000 400,-140,-540,-270,-2.700,-3.240,-0,041 79,7 %

A: Produced parts before regrinding

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Factors influencing tool life

tool steel production process tool steel forming process tool material geometry of the tool

tool manufacturing

lubricant supply

heat treatment

lubricant

forming process

surface finishing

forming material

end finish

second heat treatment

bonding strength

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Conclusion
advantageous tool steel selection provides a lot of possibilities a) to improve the lifetime of tools b) to increase the efficiency and to reduce the total costs The heat treatment process is an importent device to achieve required micro structure and needed properties

The ideal prerequisites for later surface coatings should be accomplished during the stage of construction by advantageous tool steel selection, heat treatment, dimensioning and design!

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Milling cutter DE-PMD30 + PVD-TiN 66,5 67,5 HRc

Thank you for your attention