Cast Tool Steels Uddeholm - Swereaextra.ivf.se/verktyg/download/Cast Tool Steels Uddeholm.pdf · 2007-03-21 · Uddeholm decided for 2006 to offer tool steel castings for other automotive

Andreas Johansson, Strategic Market Development-Automotive

Cast Tool Steels

Andreas Johansson Strategic Market Development-Automotive2

Agenda

Uddeholm AutomotiveUddeholm Cold Work and Cast productsProduction process and simulation for castingsSummary

Uddeholm Automotive


Uddeholm Automotive Introduction

Approximately 50% of our sales is for automotive industry.

Competitive advantages – Complete Product program– Inhouse R&D– Technical support and

application know how– Global salesorganisation– International Account

Management


Uddeholm Automotive Cold Work


Standard gradesIngot casting • Rigor• Carmo/Calmax• Sleipner

Ingot casting Ingot casting • Rigor• Carmo/Calmax• Sleipner

Star grades

PM• Vanadis 4 Extra• Vanadis 6• Vancron 40

PMPM• Vanadis 4 Extra• Vanadis 6• Vancron 40

Premium grades

Spray forming• Roltec• Weartec

Spray formingSpray forming• Roltec• Weartec

ESR• Caldie

ESRESR• Caldie

Uddeholm Automotive Cold Work

Uddeholm Cast Tool Steels


BackgroundTraditionally only wrought material because of its superior

mechanical properties.One of our customers approached us with a need for

– Higher quality for tool steel castings – Reduced leadtimes– Better delivery accuracy

Uddeholm decided to launch a pilot project with this customerResponse from Pilot project customer:

– Leadtimes for tool steel castings is reduced– Delivery-precision is much improved– The quality is better than competitors

Uddeholm decided for 2006 to offer tool steel castings for other automotive customers


Leadtime

Focus on lead time and flexibility Standard lead time is 3 weeks, from arrival of pattern until

shipment from HagforsPattern making adds approximately 1 week to the standard

lead timeClose integration and coordination with external model maker We continuously strive towards even more competitive lead

times and increased flexibilityIt is normally already possible to agree on even shorter lead

times


Rough distribution of leadtime

3 1 1 1 1 4 1 4 2 1 1 3

TransportUnpack/InspectionCoatingFormingCastingCoolingCleaningHeat TreatmentBlastingPackingDelivery preperationTransport

Total 23 days


Quality

A certificate of the chemical analysis and hardness is included for each casting.Simulation of flow and solidificationGood quality raw materialAdvantages for the customer

– Good quality castings – Gives the best possible mechanical

properties– Predictable behavior in machining,

heat treatment etc…Advantages for Uddeholm

– It gives us a stable and predictable production process


Technical Support and R&D

Every day technical support is provided by the staff of the foundry as well as the responsible outdoor salesman.

Uddeholm central R&D can offer technical and metallurgical knowledge and experience as well as testing facilities that conventional foundries do not have

Together with customers Uddeholm has several development projects that aims to increase the knowledge in the field of tool material and sheet metal processing

As an example of this we have now included cast tool steel in our test and research program with SSAB with the aim to find optimalcombinations of tool steel castings and AHSS materials

Another example is the development project of mixed castings


Camito castings trials


Standard product program

-Caldie Cast

1.2382 (1.2379 as cast)Sverker 21 Cast

-Sleipner Cast

1.2333 (1.2358 as cast)Carmo/Calmax

1.7140Fermo Cast

WS numberUddeholm


Cast Materials in general compared to wrought steel

No subsequent process steps like for example:– ESR– Hot forging– Rolling

This affects the properties of the material mainly in the following way:– Reduced cleanliness– Reduced ductility– Reduced toughness

The casted materials are in relation to each other similar to the wrought material.

The spread in properties are in general bigger for castings than for wrought steel.


Flexibility of design


”Carmo concept”


Succes story: Caldie and Carmo Cast

Success with Caldie and Carmo CastPredictable wearWeldabilityGlobal support

Securing quality by simulation


Production process tool castings

CAD file PolystyrenPattern Casting



Solidification simulation


Solidification simulation result


Recommended changes


With ingates and riser


Second solidification simulation


Simulation of flow

Summary


Summary

Uddeholm has a complete product program for the automotiveindustry

We offer reduced leadtime for tool castingsWe offer improved quality of castings We offer a total cold work tool steel concept consisting of:

– Wrought bar material– Castings– Welding rods– Granshots

Each productgroup is segment leaders in terms performance and innovation

We have the capability to support the automotive toolingindustry also in techncial development, via inhouse research and via projects with external partners

TRUST IS SOMETHING YOU EARN, EVERY DAY.

Documents

Cast Tool Steels Uddeholm - Swereaextra.ivf.se/verktyg/download/Cast Tool Steels Uddeholm.pdf · 2007-03-21 · Uddeholm decided for 2006 to offer tool steel castings for other automotive