Casted press hardening dies for optimum heat transfer

Purpose and goal

The project will investigate whether casting can be used as method to produce forming parts for press hardening tools to achieve more efficient cooling through the possibility of designing more optimal cooling channels. It should also investigate whether the casting material can withstand the thermal and mechanical loads in the process for press hardening tools. Finally, the project has evaluated modern CFD- and FEM-tools to determine if they are sufficiently developed to support optimization in the development of casted forming parts and this has been achieved in the project.

Expected results and effects

The result shows that casting as a method to produce forming parts for press hardening tools works and provides mechanical properties in the cast material, sufficient for the intended application. Furthermore, the project has shown that modern CFD and FEM analysis tools provide good support in designing the cooling channels´ shape and location in order to achieve optimal heat dissipation and cooling performance. Based on the project results, Conex has offered and subsequently won a commercial tool project based on casted form parts and the first tools will be tested during w.7 at Conex.

Planned approach and implementation

The project layout has worked well. Conex has designed a forming part with cooling channels adapted for the casting process. The work has been done in collaboration with MEFOS and SWECAST where MEFOS has performed flow and heat transfer calculations. SWECAST has done the manufacturing preparation for the forming part, 3D-printed a sand mould and produced a casted prototype forming part. Finishing of the casted forming part has been done by Conex. Hardness measurement on the tool part has been performed on form surfaces and structure to analyze mechanical properties and wear resistance.