A/SP Project Manager: Eric McCarty– A/SP

Objectives:
? Study die wear durability of various tooling materials and coatings for flanging operations on bare DP1180 steel.
? Update OEM tooling standards based on the test results.

Project Phases:
? Phase 1: Can we use the current die materials and coatings in production of 980 grade steels? (2015)
? Phase 2: If not, what die materials and coatings should we use to form 1180 grade steels? (2016)
? Phase 3: Why did some of the die inserts perform better than others? (Ongoing……)

? Over 100k hits;
? 33 die inserts;
? Combination of 10 die materials and 9 coatings;
? 42 Ton testing materials;
? Preserve one panel every 500 hits;

? The die material and coating method in large volume production of 980 and lower grades steels was not suitable for forming next generation AHSS, 1180 grade steels.
? The die materials, such as ductile iron and low alloy cast steel, should not be considered for die design in stamping 1180 grade steels.
? The inserts #7 (TD2, Cool Sheet), 9 (Cast Caldie, Concept+Most), 10 (DC53, Concept+Most), and 11 (TD2, Duplex+Variantic) are the potential candidates for stamping 1180 grades steel in mass production.
? The die wear performance was influenced by combination of die material selection, die material hardness, die design, coating method, die surface roughness, die insert manufacturing, die alignment, and AHSSs.