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Design optimization of hot forming tools by numerical
thermal analysis
Dr. Dhananjay Kumar, Vishal Shirsat, Vikas Sharma, Chandraprakash Sarpate
KLT Automotive and Tubular products Ltd.
Pune Maharashtra INDIA
Abstract: Hot forming or press hardening is the one of the technique for forming a high
strength steels into complex shape components. Quenching of a component inside die is
the important process step which decides quality of the component in hot forming.
Ideally uniform properties are required which is possible by same cooling rate at each
and every location. For getting nearly same cooling rate, design of hot forming tools
brings many challenges. Numerical simulation technique can be used for overcoming
many problems encountered during design of hot forming tools. Also, design cycle time
for hot forming tools can be reduced significantly. In this paper, an attempt is made to
design hot forming tools for one of the hot stamped component by transient and steady
state thermal analysis. Mainly, cooling channel network was optimized to bring average
tool surface temperature in range of 100ºC to 200 ºC at the end of forming operation.
During optimization, it was also tried to make temperature distribution as uniform as
possible over the surfaces of the die.
Keywords: Hot forming, Optimization, Thermal analysis, Cooling Channel.
INTRODUCTION
It is known that a crucial part of the production of a hot forming tool is essentially the
development of a die-face design aiming a tooling surface geometry that gives a fully
developed blank shape a defect-free forming form within the necessary quality
constraints and the requirements for high security, low weight, and good fuel economy
have become the pushing factors for car manufacturers in the past years. The realization
of customers’ wishes has led to the introduction of new security concepts and
consequent low-weight construction. In the field of the car body construction the use of
highstrength steels led to an improved crash behavior and at the same time lowers
weight. Such highly stress able components can either be produced in a cold forming
process of high-strength steels or by the hot forming of boron-alloyed steels with
subsequent hardening. This process, which is referred to as hot stamping, makes it
possible to produce complex shapes with a tensile strength up to 1,500 MPa. The
components are characterized by absorbing a large amount of energy with a low degree
of deformation.
The properties of the tool material and the complex interaction between the
thermal cycling and the mechanical conditions determine the behavior of the material
during the tool’s work cycles. Elasto-viscoplastic behavior models have successfully
been utilised to simulate the non-isothermal stress strain response of material exposed to
thermomechanical load conditions. However, running numerical simulations is
necessary for an increased understanding of the behaviour of the material during
thermal cycling, as well as for the development of new models to describe the cyclic
material response.
ADVANTAGES OF HOT FORMING
Good dimensional accuracy.
Extremely high strength and good ductility.
Excellent crash behavior.
Very high potential to reduce weight
REQUIREMENTS OF THE COOLING SYSTEM FOR THE THERMAL
ANALYSIS
The cooling phase does not only influence the economy of the process but also the final
properties of the component. The objective is to quench the hot part effectively and at a
constant rate and to provide a cooling rate of at least 27 K/s while martensite is formed.
The die cooling system is economical if a fluid coolant, such as water, is used, which
flows through cooling ducts around the contours of the component. In the test tool the
cooling ducts are realized with drill holes. In order to provide an effective cooling
system, the four tool components punch, counterpunch, female die, and counterholder
are all actively cooled.
FACTORS INFLUENCING THE HEAT FLUX (IN THERMAL ANALYSIS)
The flow of heat of the drawn component is dependent on various influencing factors.
In Fig. 1 the flow of heat from the drawn part to the coolant is shown and classified in
the following three respects: heat transfer from the component to the tool, heat
conductivity within the tool, and heat transfer from the tool to the coolant. The flow of
heat from the component to the coolant can be optimized with various parameters. The
heat transfer between component and die plays an important role. The contact surface
should be ideal if possible, i.e. it should not exhibit a scale or a gap. The heat
conductivity within the tool can be considerably influenced by the choice of the tool
material. Another important factor with respect to heat drain is the design of the cooling
ducts, which is defined by the size, location, and distribution of the cooling ducts. The
design has to take into account that the coolant should flow turbulently and gas bubbles
due to boiling or tapped blind holes have to be avoided during the operation of the tool.
The heat drain can be accelerated by using a coolant with a low temperature, in order to
increase the temperature difference between the coolant and the tool and therefore the
resulting heat flux. This article focuses on the optimization of the geometric design of
the cooling system. The reader will be provided a newly developed method with which
the complex problem of optimization can be solved.
Figure 1 : The Heat Balance of the part and cooling medium
OPTIMIZING THE DESIGN OF THE THERMAL SYSTEM
The basis for this optimization method is formed by an design process and thermal
analysis, with which the cooling ducts can be optimized for a given set of boundary
conditions and parameters.
The optimization can be classified as follows:-
As a first step the design of the cooling ducts is optimized for each component
separately. The calculations for the optimization require information on the geometry
and the boundary conditions. Each tool component is characterized by areas which are
thermally or mechanically loaded or unloaded and areas in which holes can be drilled
for cooling ducts or not. Furthermore areas have to be chosen which are suitable for
supply drill holes for the inlet hoses. For each component a set of parameters has to be
predetermined, consisting of the number of drill hole chains, the number of drill hole
segments per chain and the drill hole diameters. The optimization can be carried out
considering the criteria cooling intensity and homogeneity. The optimization of the
design of the cooling ducts is calculated separately for each component and for
thermally-stationary conditions, i.e. the source of heat (blank) and the heat sink (cooling
medium) are constant with respect to time.
DESIGN OF THE HOT FORMING TOOL
The design of the test tool, which is developed for the hot forming process within the
framework of a research project, is to be optimized with respect to cooling. The die
kinematics and the test geometry of the hot forming tool in Fig. 2. The punch is
mounted on the lower die. In the drawing operation counterpunch and female die are
traversed downwards in one movement. The initial blank consists of sheet metal
(material: 22 MnB5).
Figure 2 : Hot Forming Tool
FINITE ELEMENT APPROACH
The Finite Element model has been developed to find the thermal characteristics of for
hot forming tools. The model has been developed with the following assumption:
Initial temperature of the blank holder, upper and lower dies (all nodes including
interior nodes) was assumed to be 100 ºC. The temperature of these bodies at the
end of the solve should be close to 100 ºC.
Flow in the tubes is assumed to have reached steady-state (developed duct flow)
The turbulence in the tubes is assumed to be negligible
Convection is the only mode of heat transfer between coolant and tubes
Radiation and convection are only modes of heat transfer between components
and ambience (20 ºC)
View factor to ambience is assumed to be 1.0
Convergence Criteria:
Max temp. change: .001 ºC
Convergence limit: 1.0e-8
Solution Control
Time integration: Backward
Calculation step: 0.1
Output step: 0.5
Duration of solve: 9.5 sec
Forming time: 1.5 sec
Quenching time: 8.0 sec
Duct flow boundary condition at 18 L/min for each tube
Convection coupling between ducts and dies.
Thermal coupling between the mating components (4000 w/m2k).
For the qualitative and quantitative estimation of the approaches a transient FE
calculation of the tool was carried out. In this case only the cooling phase in the closed
die is simulated; the preliminary forming operation is neglected due to the rapid
drawing operation. The engineering material used for the tool is HTCS 150 shown in
Table 1, and the deep-drawn part of the blank material is steel 22MnB5.
Table: I Thermal and Mechanical properties of die material
Die material properties Value
Young modulus (GPa) 210
Poisson ratio 0.3
Density ( kg/m3) 7850
Thermal conductivity (W/ m.K ) 68
Specific heat (J/Kg K) 470
The geometric models of the forming tool made in CATIA commercial software and
then imported into NX-UNIGRAPHICS 7.5 to carry out the numerical thermal process
simulation. The dimensions of the tool parts are given below with CAD model:
[Fig. 3 to 7],
Figure: 3 Blank CAD Model
Figure: 4 Hot Forming tool dimension with CAD Model
Figure: 5 Punch and cooling holes dimension with CAD Model
Figure: 6 Blank dimension with CAD Model
Figure: 7 Lower Die dimension with CAD Model
Meshing of The Hot Forming Tool
The element type of volume meshed is linear tetrahedron. There are some meshing
sizes in given below for different tools parts and for cooling system.
Surface mesh size on tool face is 5mm.
Surface mesh size on mating face of upper & lower die is 8mm.
Bulk mesh size is 22mm.
Mesh size on blank holder is 22mm.
Mesh type for coolant – 1D beam elements.
Element size for 1D duct mesh is 3mm.
Number of 3D tetrahedron elements is 1124705.
Number of 1D duct elements to simulate coolant is 8595.
Surface mesh size on the inner surface of tubes (interface between coolant and
die) is 8mm for Convection coupling was provided between the coolant and the
surface mesh.
The complete mesh model of the hot forming tool is given below form fig. 8 to 12.
There are different mesh sizes and mesh element, we have already discussed in above
paragraph.
Figure: 8 Meshed model of the blank
Figure: 9 Meshed model of the Punch (Upper Die/Top and Bottom)
Figure: 10 Meshed model of Blank holder ( Top and Bottom)
Figure: 11 Meshed model of the lower die
Figure: 12 Meshed model of cooling ducts
Procedure for Numerical Thermal analysis
The initial temperature of the blank is 940 ºC and the temperature of blank when put on
die is 810 ºC. Further parameters which were used with respect to initial values and the
heat transfer values. Before starting the process giving some boundary conditions like
lower die is fixed and only upper die (punch) move top to bottom. The blank hold on
blank holder. After that giving some stroke on the punch then punch slightly move on
blank at cycle time. The die movement in air 0.5 sec and the quenching time inside the
die is 8 sec considered. Find the Actual forming time is 1.5sec and Transfer time for
replacing completed component with new component is 3.5 sec. There are some
temperature plots at 0.5 and 9.5 sec. Figure 13 to 22 shows the temperature plot at 0.5
sec & 9.5 sec with all faces of the tool and for cooling ducts, the plots shows the
temperature effect on the tool and ducts. Temperatures are depends on time, if rises the
time, so found the change the effect of temperature on tools.
Numerical Simulation Results
Figure: 13 Temperature plot at 0.5 sec – Blank top face
Figure: 14Temperature plot at 0.5 sec – Blank Bottom face
Figure: 15 Temperature plot at 0.5 sec – Upper die
Figure: 16 Temperature plot at 0.5 sec – Lower die
Figure: 17 Temperature plot at 0.5 sec – Coolant
Figure: 18 Temperature plot at 9.5 sec – Blank Top Face
Figure: 19 Temperature plot at 9.5 sec – Blank Bottom Face
Figure: 20 Temperature plot at 9.5 sec – Upper die
Figure: 21 Temperature plot at 9.5 sec – Lower Die
Figure: 22 Temperature plot at 9.5 sec – Coolant
RESULTS AND DISCUSSION
Figures 13 to 22 show the temperature plots predicted by the numerical method of FE
analysis for the time step of 0.5 and 9.5 respectivrly. The hot spot generated due to
temperature on the blank, lower die and upper die tools has been compared. As it is
clear from the figures (24-27), the hot spot area around the hot forming tool (inside and
outside) for lower die and blank is larger than that of the upper die. The reason for this
improved cooling performance with small drill hole diameters can be seen in the
analysis of the spread of temperature in the tools.
It is quite clear that the thermal induced hot spot in the deformation caused by
lower die and blank is more than that caused by the upper die. The important point to
note that the geometry of hot forming tool is important to defining the temperature
characteristics of hot forming tool material. Comparisons of the qualitative as well as
quantitative level are highly encouraging.
Figure: 23 Hot spot on top face of blank
Figure: 24 Hot spot on bottom face of blank
Figure: 25 Hot spot on Lower die
Figure: 26 Hot spot on Upper die
Figure: 27 Hot spot on Coolant
CONCLUSION
In the present work, numerical thermal simulations were done for the actual hot forming
tool. A methodology has been developed which makes it possible to optimize the
geometrical design of the Numerical thermal (cooling system) of hot stamping tools.
Currently the optimization software only offers the use of hot forming tool and
Numerical thermal components. This way numerical simulation helps to speed up total
product development process and find out the thermal effect on the die tool material.
However, experimental trial has to be done to verify the numerical simulation results.
PRESENT STATUS IN INDIA
Though, nearly 3.18 million vehicle has been manufactured in India in the year 2010
with growth rate above 30%, presently we do not have any Hot stamping production
line for automotive application. KLT is putting up first time such facility with their
European teachnology supplier with a capacity of 1 million strokes/ year with cycle
time avearge of 18 seconds and in each stroke 2-4 components will be produced. KLT is
also working with local steel supplier to develop required grade of B-Mn steel. Further,
we are also working with major Indian automotive in order to make such components
integrated in existing/ new vehicle program which is being envisaged. With
implementation of New Safety Crash norms from 2013, we expect a major growth in
Hot stamping technology in India as we foresee by 2020 with total vehicle production
going beyond 10 million and on avearge atleast 10 components will be required in each
vehicle through this route, atleast 50 such line will be required only to meet the
domestic requirements.
ACKNOWLEDGMENT
Here we take this opportunity to thank our CMD, Mr. Bhavin Thakkar for giving us
necessary permission to present this paper as many of the information are proprietary
with commercial significance
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