High Strength Steel Stamping Design Manual - Auto/Steel Partnership

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Manufacturing Process Product Design Material Section 4 – Die Design and Construction Guidelines for HSS Dies
Section 4 – Die Design and Construction Guidelines for HSS Dies General Guidelines for Die Design and Construction Draw Dies Higher than normal binder pressure and press tonnage is necessary with H.S.S. in order to maintain process control and to minimize buckles on the binder. Dies must be designed for proper press type and size. In some cases, a double action press or hydraulic press cushion may be required to achieve the necessary binder forces and control. Air cushions or nitrogen cylinders may not provide the required force for setting of draw beads or maintaining binder closure if H.S.S. is of higher strength or thickness. Draw beads for H.S.S. should not extend around corners of the draw die. This will result in locking out the metal flow and cause splitting in corners of stamping. Draw beads should “run out” at the tangent of the corner radius to minimize metal compression in corners, as shown in figure 16 on page 47. Better grades of die material may be necessary depending on the characteristics of the HSS, the severity of the part geometry, and the production volume. A draw die surface treatment, such as chrome plating, may be recommended for outer panel applications. Form and Flange Dies Part setup in form and flange dies must allow for proper overbend on all flanges for springback compensation. Springback allowance must be increased as material strength increases; 3 degrees for mild steels, but 6 degrees or more for HSS. Punch radii must be fairly sharp. 1t for lower strength steels. Higher strength steels may require larger radii, but keeping them as small as practical will reduce springback in the sidewalls. Flange steel die clearance must be held to no more than one metal thickness clearance to reduce springback and sidewall curl. Form and flange steels should be keyed or pocketed in the casting to avoid flexing. Flange steels should be designed to wrap over and coin the flange break in order to set the break and reduce springback. See figure 17 on page 48. Die strength must not be compromised with light-weight die construction. High strength steel will require a stiffer die to resist flexing and the resultant part distortions, especially for channel or “hat-section” parts. This type of part can also cause serious die damage if double blanks occur. Cutting Dies To reduce press tonnage requirements and extend die life, a minimum shear of four to six times metal thickness in twelve inches of trim steel length is recommended. To reduce die maintenance, maximum trim angles should be about 5° to 10° less than those used for mild steel. Trim steels should be keyed or pocketed in casting to avoid flexing. Die clearance should be 7 to 10% of metal thickness. Page 46
Page 1 and 2: AK Steel Corporation Bethlehem Stee
Page 3 and 4: Table of Contents Introduction . .
Page 5 and 6: Executive Summary The importance of
Page 7 and 8: Section 1 - Material Characteristic
Page 15 and 16: Manufacturing Process Product Desig
Page 17 and 18: Section 2 - Product Design Guidelin
Page 19 and 20: DOOR OUTER PANEL 100% 90% Section 2
Page 27 and 28: Section 3 - Die Process Planning Gu
Page 31 and 32: Sketch #2 - Form Die (Upper Pad) Se
Page 33 and 34: WORK TRAVEL UPR. PAD Section 3 - Di
Page 35 and 36: LOCK STEP Section 3 - Die Process P
Page 39: Section 3 - Die Process Planning Gu
Page 43 and 44: 1 2 STIFFENING DART Section 4 - Die
Page 45 and 46: Section 5 - Die Tryout Guidelines f
Page 49 and 50: Section 6 - Glossary and Case Studi
Page 67: Section 6 - Glossary and Case Studi

High Strength Steel Stamping Design Manual - Auto/Steel Partnership

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