Selection of tool materials and surface treatments for improved galling performance in sheet metal forming

Abstract

Galling is a known failure mechanism in automotive stamping. It results in increased cost of die maintenance and scrap rate of products. In this study, rectangular pan and U-channel stamping experiments are used to (1) investigate the effect of stress states on galling performance in sheet metal forming, (2) select proper tool materials and surface treatments for improved galling properties, and (3) differentiate galling performances of bare and coated steel sheets. The results indicate that problems with galling are of major interest at the regions where sheet materials deform under the action of compressive stress. For the four investigated tool materials, Mo–Cr alloy cast iron shows the best galling performance. A combination of hardening, surface polishing, and Cr coating is suggested as the optimum tool treatment in the forming of bare high-strength steel. Hot-dip galvanized steel shows better galling behaviors than galvannealed and bare steel sheets. Galling performances of hot-dip galvanized and bare steels are improved with increased hardness of the forming tool. However, galvannealed steel results in severe galling when the hardness of the forming tool is very high.