Doosan Heavy Industries & Construction DOOSAN PLASTIC MOLD …€¦ · productivity and rationalization of production. DOOSAN’s Plastic Mold Steels DOOSAN BRAND D/N REFERENCE SPECIFICATION

Doosan Heavy Industries & Construction

DOOSAN PLASTIC MOLD STEEL

GLOBAL LEADER IN POWER & WATER

Doosan has continued to research and develop technology for producing outstandingmold steel, which is now being supplied for the benefit of customers worldwide.Plastic mold steel from Doosan is also accelerating the development of industry.

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION


CONTENTS

INTRODUCTION ‥‥‥‥‥‥‥‥‥‥‥‥ 04

PLASTIC MOLD STEELSHP1A / HP4A(D1) / HP4MA(D2) ‥‥‥‥‥ 06

HIGH QUALITY PLASTIC MOLD STEELSHP70 / HEMS1A ‥‥‥‥‥‥‥‥‥‥‥‥ 10

PHYSICAL PROPERTIES ‥‥‥‥‥‥‥‥‥ 13

MANUFACTURING PROCESS ‥‥‥‥‥‥‥ 14

03


INTRODUCTION

Mirror polishability

General Products Semi-transparentProducts

transparentProducts

Super mirrorfinish ProductsH

ardn

ess HP1A

HP4A(D1)

HP4MA(D2)

HP70

HEMS1A

Polishing Property(Schematic Diagram)

�


0�

Doosan’s Plastic Mold Steel “HP”

DOOSAN Heavy Industries & Construction Co., Ltd. (DOOSAN) has been producing various types of casting& forging products for the many years ranging from power generator, chemical vessel, steel mill, shipbuilding to cement industries.

Since being founded, DOOSAN has also supplied plastic mold steels and tool steels to the high technologysectors such as electric, electromagnetic, optical, telecommunication industries as well as the fields ofsemiconductors, precision machinery, construction machinery, automobile, etc.

DOOSAN is very pleased to be given the chance to supply its products to the world. As mentioned above,its products are well known for their excellence in quality. Doosan is proud to inform you that it has patentsfor plastic mold steels in Korea as well as acquired certificate of ISO 9001 (ANSI / ASQC Q91).

DOOSAN will continuously do its very best in improving the quality of plastic mold steels to its limit. Wewill promise satisfaction to all of our customers.New types of high-quality free-cutting steel for plastic moldings, HP series plastic mold steels, have beendeveloped under a strict quality assurance system with DOOSAN’s modern facilities.

Compared with the conventional steel materials of other companies, the machining time for our newproducts can be reduced by a maximum of 40%. Because of special alloy elements in our HP series plasticmold steels, one can obtain better etching workability, polishing workability and weldability than in manyother products.

As a result, not only is the efficiency of metal mold work improved and the service life of the cutting toolsgreatly extended, but one can also make excellent plastic products. HP steels and HEMS1A are highperformance and high-precision plastic mold steel.

Use of our newly developed HP steels and HEMS1A can make a major contribution to the improvementproductivity and rationalization of production.

DOOSAN’s Plastic Mold Steels

DOOSANBRAND D/N

REFERENCE SPECIFICATION SUPPLIEDCONDITION

APPLICATIONSDIN AISI JIS ASSAB

HP1A1.1210

Improved10�0

ImprovedS��C

Improved- Prehardened

· General purpose large size mold base

HP4A(D1)1.2311

Improved4140

ImprovedSCM44oImproved

618Improved

Prehardened · Core & Cavity · General purpose mold for Mass-production

HP4MA(D2)1.2738

ImprovedP20

ImprovedSNCM

Improved718

ImprovedPrehardened

· Higher hardness mold · Bumper mold · General purpose mold for Mass-production

HP70 -P21

ImprovedDaido’sNAK80

- Prehardened · High grade mold base for mirror surface & EDM requirement

HEMS1A1.2083

Improved420

ImprovedSUS420J2Improved

STAVAXImproved

Annealed

· Corrosion resistant precision plastic mold · Glass mold & TV braun tube mold

HP1A / HP4A(D1) / HP4MA(D2)

Material HP1A HP4A(D1) HP4MA(D2)

C >0.�0 0.2� ~ 0.3� 0.2� ~ 0.3�

Ni <0.�0 0.20~0.�0 0.20~0.�0

Cr - 1.00 ~ 1.�0 1.�0 ~ 2.00

Mo - 0.20~0.40 0.30~0.60

SpecialAlloy

Added Added

Material Characteristics

HP1A

· General Purpose for Plastic Molding · Outstanding Machinability · Less Residual Stress and Distortion

HP4A(D1)

· Excellent Machinability · Superior Cleanliness, Weldability and Photo-etching · Better Hardness Distribution

HP4MA(D2)

· Better Machinability · Outstanding Hardness Distribution and Wear Resistance · Superior Cleanliness and Photoetching

Manufacturing Characteristics

MELTING

· Superior Cleanliness due to High Vacuum Degassing Process

FORGING

· No Solidification Defect by Using 130MN & 42MN Press

HEAT TREATMENT

· Excellent Mechanical Properties by Optimal Heat Treatment

Main Concepts of Developing HP4A(D1) & HP4MA(D2)

· Adopting new concept in alloy design to make up for weak points with maintaining strong points · Optimizing quality heat treatments to get mechanical properties.

Quality Properties

█ Chemical Compositions(Unit :wt%)

Material HP1A HP4A(D1) HP4MA(D2)

SurfaceHardness

HS 28~33 HRc 28~32 HRc 31~34

YieldStrength(N/㎟)

3�0 ~ 4�0 6�0 ~ 800 7�0 ~ 900

TensileStrength(N/㎟)

700 ~ 800 800 ~ 900 900 ~ 1100

█ Mechanical Properties



07

Har

dnes

s(H

Rc) 36

34

32

30

28

26

24

22

20

-200 -100 0 100 200

HP4MA (D2)HP4A (D1)

Distance from center(mm)

Stre

ngth

(n /

)

HP1A HP4A (D1) HP4MA (D2)

700

600

500

400

300

200

1000

900

800

100

cross sectional Hardness distributionHardness is uniformly distributed throughoutthe cross sectionYield tensile

photo etching

there is no serious trouble in the most segregated part of 770mm heavy block.

segregation

HP4A (D1) and HP4MA (D2) are superior to HP1Ain segregation.

Hp4a(d1) Hp4Ma(d2)

Hp1a Hp4Ma(d2)

Mechanical properties graph

Plastic Mold Steel-121029-2_Plastic Mold Steel-0511 12. 10. 29. 오오 3:51 Page 7


07

█ Photo etchingThere is no serious trouble in the most segregated part of 770mm heavy block.

HP4A(D1) HP4MA(D2)

█ SegregationHP4A (D1) and HP4MA (D2) are superior to HP1Ain segregation.

HP1A HP4MA(D2)

█ Mechanical Properties Graph █ Cross Sectional Hardness DistributionHardness is uniformly distributed throughoutthe cross section



TEST CONDITION

• Cutter : M41�SP-0�R-12• Insert : SPKN1203EDTR-HP/ TT7070

█ Machinability

HP4A(D1) & HP4MA(D2) give 2 timeslonger in life of tool and shorter inmachining time than DIn materials.

• V=2�0m/min f=0.1�mm/tooth• d=2.0mm Center cutting dry

Hp1a

repair welding Manualdescription

Hp4a(d1) Hp4Ma(d2)remarks

AWSER70S-4ER70S-6

AWSER80S-B2ER80S-G

AWSER80S-B2ER80S-G

ER9oS-B3

Welding Rod : 1.6ø, 2.4ø

Fuel : LnGFuel Pressure : 0.5 kg/cm2

tP (Holding temperature)HP1A : 270 20HP4A(D1) : 350 20HP4MA(D2) : 320 20

Required Polishing and Etching Workability

250 50(200~300)

WeldingPost Heating

(250~350 )Preheating

WeldingSlow cooling( 50 /hr)

300

PWHt

(500~600 )

(200~350 )Preheating

Filler Metals

Preheat temp.

Post Heat treatment

Post-Weld Heattreatment (PWHt)

*Slow cooled using insulating materials.

300 50(250~350)

250 50(200~300)

30(min) / inch

1-2hr

*

*

procedures for repair welding

In case of design change and defects during operation, repair welding has to be performed. Due to high strength of mold steel repair welding requires the extreme care and strict supervision.

max.100 /hr

tP

VBm

ax (m

m)

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0.021 3 40

1.2311

Hp4a(d1)

Cutting Distance (mm) Cutting Distance (mm)

life of tool

VBm

ax (m

m) 0.7

0.6

0.5

0.4

0.3

0.2

0.1

0.0

21 3 40

1.2738

1.6 3.3 1.5 3.2

Hp4Ma(d2)

life of tool

Machinability



HP4A(D1) & HP4MA(D2) give 2 timeslonger in life of tool and shorter inmachining time than DIn materials.

• Cutter : M415SP-05R-12

• Insert : SPKn1203EDtR-HP/ tt7070

• V=250m/min f=0.15mm/tooth

• d=2.0mm Center cutting dry

test condition


cutting Distance(m) cutting Distance(m)

9


09


09

weldability

Improved consistency in hardness before/after PWHt.

Distance from the center (mm)

Har

dnes

s (H

v) 500

450

400

350

300

250

200

150500

450

400

350

300

250

200

150

42 6 8 100

as weld

Hp4a(d1). surface

after PWHt

as weld

Hp4a(d1). center

after PWHt

Vick

ers

Har

dnes

s (L

oad:

5kg) 650

600

550

500

450

400

350

300

250

200

150

-25 -20 -15 -10 -5 0 5 10 15 20 25

Hp4Ma

Hp4Ma(d2)

base HaZ weld HaZ base

weld HaZ base

as weldafter PWHt

after PWHtas weld


█ WELDABILITY

Improved consistency in hardness before/after PWHT.


HP70 / HEMS1A

MaterialChemical Composition(wt, %)

C Ni Cr Mo Special Alloys

HP70 < 0.2� > 2.00 - < 0.�0 Added

HEMS1A 0.2�~ 0.30 ≤ 0.30 12.00 ~ 12.�0 ≤0.�0 Added

Characteristics

HP70

· Maintain excellent surface finish · Uniform hardness throughout the cross section · Extreme hardness and superior wear resistance · Excellent electric discharge machinability

HEMS1A

· Excellent corrosion resistance · Excellent mirror finishing · High precision · Uniform hardness throughout the cross section

█ Chemical Compositions

Quality Properties

█ Vacuum-Degassing Process

Our free cutting steels are vacuum-degassed and forged.They have 1) excellent cleanliness 2) no pin holes 3) desegregation of alloy elements.

Material Yield Strength(kgf/㎟)

Tensile Strength(kgf/㎟)

Elongation(%)

Reduction of Area(%)

Surface Hardness(HRc)

HP70 100 ~ 11� 120 ~ 13� > 17 > �2 37 ~ 41

HEMS1A 60 ~ 70 7� ~ 8� > 2� > �0 23 ~ �2

█ Mechanical Properties

11


Har

dnes

s(H

Rc)

Har

dnes

s(H

Rc)

Distance from center (mm)

50

45

35

40

30

26

250 200 150 100 50 0 50 100 150 200 250

Hp70

Cutt

ing

Forc

e(n

)

Cutting Depth (mm)

• table Moving Speed: 160mm/min.• Face Milling ConditionCutting Speed: 261m/min.Insert type: SPKn1504EDRLubricant: no

Hp70 Hp70

4700c, 5hr

Hp70

520 0c, 5hr

Hp70

Har

dnes

s(H

v)

Har

dnes

s(H

v)

Distance from the surface (10-2mm) Distance from the surface (10-2mm)

Heat AffectedLayer

• EDM Condition: M/C: tron150c: Electrode: Copper(8ø ): Surface roughness: Ra4

800120

100

80

60

40

20

800 500

450

400

350

300

250

200

0 2 4 6 8 10 12 14 16 18 20

700

600

500

400

300

0 5 10 15 20 25 30 35 40

00 100 200 300 400

700

600

500

400

300

200

1.0 1.5 2.0

tens

ile S

tren

gth

(kgf

/mm

2 )

temperature (0C)

Machinability High temperature tensile properties

nitriding characteristics electric discharge Machining

cross-sectional Hardness distribution

HeMs1a

0

71

60

50

39

30

50 100 50 0Distance from the surface (mm)

(after Q+t)


11



Har

dnes

s(H

Rc) 65

60

55

50

45

40

35

30

25

100asquenched 200 300 400 500 600

HeMs1aQuenching temp. : 1025 0C

tempering temperature (0C)

tempering Hardness curve

polishing workability

Material remark

Hp70

HeMs1a

0.019

ra.( ) rmax.( )

0.01

0.167

0.031 Diamond paste use

Clea

nlin

ess

(%)

0.14

0.12

0.10

0.08

0.06

0.04

0.02

0

Wei

ght L

oss

(g/

g) 0.20

0.15

0.10

0.05

0.00

5% hydrochloric acid

HEMS1A steel, being treated with vacuum-degassingand ESR process, shows an excellent cleanliness.

MaterialQuenching (0C)

1000 ~1050 oil cooling

100 ~ 500 45 ~ 52

23 ~ 33550 ~ 700

tempering (0C)

Heat treatment conditions

HeMs1a

surface Hardness

(HRc)

HP70 / HEMS1A


Heat treatment

AISI 420 HEMS1A

cleanliness

AISI 420 HEMS1A

corrosion resistance

Fig. shows workability of polishing and finishing.


HP70 / HEMS1A

13


Material Temperature(℃)

Thermalconductivity

(W / m·K)

Specific heat(Cal / g·℃)

Coefficient ofthermal expansion

(10-6 /℃)

HP1A

Room temperature

100200300400�00600

-�0.24248.14844.79941.031

--

-0.1160.12�0.1320.138

--

-13.7614.�11�.361�.8116.2216.�4

HP4A(D1)

Room temperature

100200300400�00600

-42.28741.86840.19337.263

--

-0.11�0.1240.1310.137

--

-13.8714.3214.821�.�81�.7�16.08

HP4MA(D2)

Room temperature

100200300400�00600

-40.61240.19339.3�637.681

--

-0.1170.1260.13�0.139

--

- 11.8213.2314.1614.6414.891�.14

HP70

Room temperature

100200300400�00600

33.117633.�78132.992031.191728.80�226.083822.1482

0.4990.�130.�440.�970.6440.7280.766

-12.8912.4413.3814.0114.1714.�6

HEMS 1A

100200300400

2�.12126.37727.21428.0�2

-

11.611.912.412.7

█ Physical Properties

PHYSICAL PROPERTIES


MANUFACTURING PROCESS

Manufacturing Process

1. Melting > 2. V.S.D(Ingot Making byVacuum Steam Degassing) > 3. E.S.R >

4. Heating > �. Forging > 6. Heat treatment > 7. Inspection

Preliminary HeatTreatment

Machining

Quality Heat TreatmentInspectionShipment

Forging

Melting

VacuumDegassing

Refining Ingot Making inVacuum Condition

Ingot Making

Heating

E.S.R

Doosan Heavy Industries & Construction SEOUL OFFICE 46� Gangnam-daero, Seocho-Gu, Seoul 137-920 KoreaTel. 82-2-�13-6114 Fax. 82-2-�13-6200

www.doosanheavy.comHEAD OFFICE AND CHANGWON PLANT22 DoosanVolvo-ro, Seongsan-GuChangwon, Gyeongnam 642-792 KoreaTel. 82-��-278-6114, 7114 Fax. 82-��-264-��1,��2

Documents

Doosan Heavy Industries & Construction DOOSAN PLASTIC MOLD …€¦ · productivity and rationalization of production. DOOSAN’s Plastic Mold Steels DOOSAN BRAND D/N REFERENCE SPECIFICATION