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Tribological Modeling in Hot Stamping Processes: Prediction of Tool Wear and Tool Lifetime on Industrial Scale

Severe abrasive wear is an unwanted phenomenon which occurs widely during hot stamping processes due to extreme process conditions like high temperatures and the absence of lubrication. Abrasive wear is a form of tool wear in which material is removed from the tools, changing the geometrical characteristics of the tools. In a longer term, abrasive wear can negatively affect the shape of formed parts and can influence the heat transfer between the tools and the sheet. Therefore, it is important to develop advanced tools to predict and control abrasive wear during hot stamping processes. More recently an advanced friction model for hot stamping processes has been introduced to accurately describe frictional behavior of 22MnB5-AlSi. This study aims to further extend the advanced friction model of 22MnB5-AlSi into an abrasive wear prediction tool by evaluating a number of abrasive wear models. Three dimensional tool scans of an industrial part are used to calibrate the abrasive wear models. This resulted in a multi-dimensional abrasive wear model as a function of temperature, pressure, strain and the cumulative sliding distance in contact between the tool and the sheet. The abrasive wear distribution and tool lifetime predictions are evaluated based on an industrial part from Volvo Cars. The abrasive tool wear locations are properly identified on the dies and a good correlation in tool wear severity could be made. However, the evolution of abrasive wear in less severe areas should be further investigated to increase the prediction capability of the proposed tool wear model.

DOI Number: 10.33313/512/B0203
Product:
2024 CHS2 Conference Proceedings
PR-512-B0203
Ciska van der Veen, Daan Waanders, Johan Hol, Mats Sigvant, Jonas Johansson, Kristoffer Trana
May 27, 2024
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