Abstract
Hot stamping uses boron (B) steel to simultaneously form parts at high temperatures while cooling the parts in a mold, which is advantageous because of the ability to freeze the forms. However, compared to conventional cold forming, this technique requires additional facilities that include heating devices and additional time for cooling after forming at high temperatures. Additionally, because of the high strengths of hot stamping parts, shear process operations after molding tend to be difficult to perform as a continuous operation via press processing; thus, most operations depend on separate laser processing, which results in lower productivity and increased manufacturing costs. This limitation continues to be the most significant problem with this technology, therefore, restricting its commercialization because of increased mold manufacturing costs and durability problems. This study investigated a low-cost, high-functionality shear mold manufacturing method for 1.5 GPa grade hot-stamped components using heterogeneous metal additive manufacturing. After the concentrated stress in steel during the shearing processes was analyzed using a multi-physical analysis, metal additive manufacturing was used to fabricate the shear mold. Its life was evaluated through trial molding and compared with that for conventional technology. Finally, the commercialization potential of the newly developed method was assessed.
Highlights
Smart Manufacturing Technology R&D Group, Korea Institute of Industrial Technology, Daegu 711-883, Korea; Abstract: Hot stamping uses boron (B) steel to simultaneously form parts at high temperatures while cooling the parts in a mold, which is advantageous because of the ability to freeze the forms
A low-cost, high-functionality shearing mold manufacturing method using heterogeneous material additive manufacturing (AM) for the efficient shearing of 1.5 GPa grade hot-stamped automobile body parts were studied, resulting in the following conclusions: (1) Two functional metal alloy powders that could be used in the functional parts of shear steel were developed based on the main principles of the metal AM process, 4
Two functional metal alloy powders that could be used in the functional parts of shear steel were developed based on the main principles of the metal AM process, the alloy components of the commercial forging material, and the hardness values after heat treatment
Summary
The most significant challenges that the automobile industry faces in the 21st century are fuel efficiency improvement through weight reduction and driver/pedestrian safety. The most widely used material for this category of strategies remains to be the B steel (22MnB5), which is typically used in the hot stamping manufacturing of 1.5 GPa grade ultra-high-strength components. From the viewpoint of production engineering, the use of laser equipment in the shearing of hot stamping parts, which is currently the most widely applied strategy, is not reasonably efficient, and it is necessary to develop an avoidance process technology to overcome this disadvantage. The commercialization of the proposed methods is limited by the higher costs In response to these problems, some advanced companies have been applying newly developed materials to the shear steel used in hot stamping parts. The commercialization possibility of the developed technology was assessed through a life evaluation using a prototype shear mold
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