Blanking

Blanking of Austenitic Stainless Steel

The most common problem for blanking of austenitic stainless steel are adhesive wear, chipping and galling. Production lot size, thickness of plates and sheets are also important factors when choosing tool steel grades. General The basic problem with austenitic stainless steel is that it is initially soft and thus prone to adhere to the tool surface. During the forming process the material gets harder through work hardening. This causes high stresses and may lead to chipping and cracking problems. Chipping and cracking is especially severe when working thicker plates or sheets. These problems can be reduced by choosing materials that is resistant to adhesive wear and chipping. Vanadis 4 SuperClean is especially good for long runs. Sleipner and Calmax are more appropriate grades for medium and short runs.

Failure mechanisms in cold work tooling Due to cyclic mechanical loading and sliding contact between work material and tool surface, the active surfaces of the tool are successively damaged. The destruction of the tool will sooner or later lead to quality problems on the formed parts (out of tolerance or bad surface qualities). The tool has then to be exchanged (total failure), reground or refurbished in some way. This maintenance procedure means production standstill and accordingly loss of productivity. It is therefore very important that the tools can resist the different types of tool failure mechanisms in order to achieve high productivity and economical production. The selection of the right tool steel is thus directly linked to the resistance of the actual tool failure mechanism for the application.

Common cold work failure mechanisms are:

Wear Chipping Plastic deformation Cracking Galling

Method for tool steel selection 1. 2. 3. Identify the dominant failure mechanism(s) Select a tool steel with properties that will overcome this / these failure mechanism(s) Match the steel choice to the length of the production run

Material recommendations The proper steel selection for the application depends primarily on the Work Material:

Type Strength

Thickness Workpiece geometry

The most critical failure mechanisms for this application are:

Adhesive wear Galling Chipping Cracking

Blanking of High Strength Sheets

The hardness of high strength sheets requires materials with high wear resistance and chipping / cracking resistance. These requirements are even higher for ultra high strength sheets used today. For ultra high strength sheets there are a need for tool materials with multi resistant profiles. General During blanking of high strength sheets, the tool clearance must be increased compared to normal sheets/plates like mild carbon steels. This is due to the higher stresses needed to penetrate the hard sheet/plate. If the clearance is too low, there is a tendency of increased galling. Too large clearance might lead too cracking problems. Powder steels like Vanadis 4 SuperClean, Vanadis 6 SuperClean have superior performance for blanking of high / ultra high strength sheets.

Failure mechanisms in cold work tooling Due to cyclic mechanical loading and sliding contact between work material and tool surface, the active surfaces of the tool are successively damaged. The destruction of the tool will sooner or later lead to quality problems on the formed parts (out of tolerance or bad surface qualities). The tool has then to be exchanged (total failure), reground or refurbished in some way. This maintenance procedure means production standstill and accordingly loss of productivity. It is therefore very important that the tools can resist the different types of tool failure mechanisms in order to achieve high productivity and economical production. The selection of the right tool steel is thus directly linked to the resistance of the actual tool failure mechanism for the application.

Common cold work failure mechanisms are:

Wear Chipping Plastic deformation Cracking Galling

Method for tool steel selection 1. 2. 3. Identify the dominant failure mechanism(s) Select a tool steel with properties that will overcome this / these failure mechanism(s) Match the steel choice to the length of the production run

Material recommendations The proper steel selection for the application depends primarily on the Work Material:

Type Strength Thickness Workpiece geometry

The most critical failure mechanisms for these applications are: High strength sheets:

Abrasive wear Chipping/cracking Plastic deformation

Ultrahigh strength sheets:

Chipping /cracking Abrasive wear

Plastic deformation Galling

Blanking of Mild Carbon Steel

All types of material failures are associated with blanking of soft carbon steel. Influencing factors are production lot sizes, material thickness and geometric complexity of the blanked part. Most types of tool steel can be used for this application. The ruling factor is Total Tooling Economy. General Problems with chipping increase with the thickness of the work material due to the increased force needed to cut through it. The risk of local welding between the tool and the work material may also increase with increased thickness. Local welding causes adhesive wear and galling. Ejecting the punch may cause cracks as the ejecting force increases with the thickness. Tooling materials with high degree of micro-cleanliness and well distibuted carbides in a homogenous matrix like Vanadis SuperClean reduce this problem. Failure mechanisms in cold work tooling Due to cyclic mechanical loading and sliding contact between work material and tool surface, the active surfaces of the tool are successively damaged. The destruction of the tool will sooner or later lead to quality problems on the

formed parts (out of tolerance or bad surface qualities). The tool has then to be exchanged (total failure), reground or refurbished in some way. This maintenance procedure means production standstill and accordingly loss of productivity. It is therefore very important that the tools can resist the different types of tool failure mechanisms in order to achieve high productivity and economical production. The selection of the right tool steel is thus directly linked to the resistance of the actual tool failure mechanism for the application.

Common cold work failure mechanisms are:

Wear Chipping Plastic deformation Cracking Galling

Method for tool steel selection 1. 2. 3. Identify the dominant failure mechanism(s) Select a tool steel with properties that will overcome this / these failure mechanism(s) Match the steel choice to the length of the production run

Material recommendations The proper steel selection for the application depends primarily on the Work Material:

Type Strength Thickness Workpiece geometry

Most critical failure mechanisms:

Abrasive wear/adhesive wear Chipping Cracking

Drawing
Deep Drawing
The proper steel selection for the application depends primarily on the Work Materials type, strength, thickness and workpiece geometry. The most critical failure mechanisms are adhesive / abrasive wear and galling. General Press drawing is the forming of a shell from a flat metal sheet into a shape that has side walls. Press drawing is normally referred to as deep drawing when the shape drawn is deeper than half its diameter. Failure mechanisms in cold work tooling Due to cyclic mechanical loading and sliding contact between work material and tool surface, the active surfaces of the tool are successively damaged. The destruction of the tool will sooner or later lead to quality problems on the formed parts (out of tolerance or bad surface qualities). The tool has then to be exchanged (total failure), reground or refurbished in some way. This maintenance procedure means production standstill and accordingly loss of productivity. It is therefore very important that the tools can resist the different types of tool failure mechanisms in order to achieve high

productivity and economical production. The selection of the right tool steel is thus directly linked to the resistance of the actual tool failure mechanism for the application.

Common cold work failure mechanisms are:

Wear Chipping Plastic deformation Cracking Galling

Method for tool steel selection 1. 2. 3. Identify the dominant failure mechanism(s) Select a tool steel with properties that will overcome this / these failure mechanism(s) Match the steel choice to the length of the production run

Press drawing
The proper steel selection for the application depends primarily on the Work Materials type, strength, thickness

and workpiece geometry. The most critical failure mechanisms are adhesive / abrasive wear and galling. General Press drawing is the forming of a shell from a flat metal sheet into a shape that has side walls. Press drawing is normally referred to as deep drawing when the shape drawn is deeper than half its diameter. Failure mechanisms in cold work tooling Due to cyclic mechanical loading and sliding contact between work material and tool surface, the active surfaces of the tool are successively damaged. The destruction of the tool will sooner or later lead to quality problems on the formed parts (out of tolerance or bad surface qualities). The tool has then to be exchanged (total failure), reground or refurbished in some way. This maintenance procedure means production standstill and accordingly loss of productivity. It is therefore very important that the tools can resist the different types of tool failure mechanisms in order to achieve high productivity and economical production. The selection of the right tool steel is thus directly linked to the resistance of the actual tool failure mechanism for the application.

Common cold work failure mechanisms are:

Wear Chipping Plastic deformation Cracking Galling

Method for tool steel selection 1. 2. 3. Identify the dominant failure mechanism(s) Select a tool steel with properties that will overcome this / these failure mechanism(s) Match the steel choice to the length of the production run

Forming (Cold)
Bending
For bending, the tool steel selection depends primarily on the work materials type, strength, thickness and workpiece geometry. The most critical failure mechanisms for bending of softer work materials ( 300 HB )are abrasive, adhesive wear and for harder ( 300 HB ) abrasive, adhesive, galling and plastic deformation. General Bending is one of the most common forming operations. It is used to change the shape of a material by plastically deforming it. In bending there is normally only deformation about one axis. Failure mechanisms in cold work tooling Due to cyclic mechanical loading and sliding contact between work material and tool surface, the active surfaces of the tool are successively damaged. The destruction of the tool will sooner or later lead to quality problems on the formed parts (out of tolerance or bad surface qualities). The tool has then to be exchanged (total failure), reground or refurbished in some way. This maintenance procedure means production standstill and accordingly loss of productivity. It is therefore very important that the tools can resist the different types of tool failure mechanisms in order to achieve high

productivity and economical production. The selection of the right tool steel is thus directly linked to the resistance of the actual tool failure mechanism for the application.

Common cold work failure mechanisms are:

Wear Chipping Plastic deformation Cracking Galling

Method for tool steel selection 1. 2. 3. Identify the dominant failure mechanism(s) Select a tool steel with properties that will overcome this / these failure mechanism(s) Match the steel choice to the length of the production run

Press Forming

Press forming is basically a cold bending operation used to shape, flange or make shallow impressions in part previously blanked out or sheared from sheet. Failure mechanisms in cold work tooling Due to cyclic mechanical loading and sliding contact between work material and tool surface, the active surfaces of the tool are successively damaged. The destruction of the tool will sooner or later lead to quality problems on the formed parts (out of tolerance or bad surface qualities). The tool has then to be exchanged (total failure), reground or refurbished in some way. This maintenance procedure means production standstill and accordingly loss of productivity. It is therefore very important that the tools can resist the different types of tool failure mechanisms in order to achieve high productivity and economical production. The selection of the right tool steel is thus directly linked to the resistance of the actual tool failure mechanism for the application.

Common cold work failure mechanisms are:

Wear Chipping Plastic deformation Cracking Galling

Method for tool steel selection 1. 2. 3. Identify the dominant failure mechanism(s) Select a tool steel with properties that will overcome this / these failure mechanism(s) Match the steel choice to the length of the production run

Shearing
Shearing / Slitting of Mild Carbon Steel
The proper steel selection for the application depends primarily on the type of work material, strength and thickness. The most critical failure mechanisms are abrasive and adhesive wear, chipping and cracking. Failure mechanisms in cold work tooling Due to cyclic mechanical loading and sliding contact between work material and tool surface, the active surfaces of the tool are successively damaged. The destruction of the tool will sooner or later lead to quality problems on the formed parts (out of tolerance or bad surface qualities). The tool has then to be exchanged (total failure), reground or refurbished in some way. This maintenance procedure means production standstill and accordingly loss of productivity. It is therefore very important that the tools can resist the different types of tool failure mechanisms in order to achieve high productivity and economical production. The selection of the right tool steel is thus directly linked to the resistance of the actual tool failure mechanism for the application.

Common cold work failure mechanisms are:

Wear Chipping Plastic deformation Cracking Galling

Method for tool steel selection 1. 2. 3. Identify the dominant failure mechanism(s) Select a tool steel with properties that will overcome this / these failure mechanism(s) Match the steel choice to the length of the production run

Shearing / Slitting of paper

Type of paper and production length and type are the major factors when selecting tooling material for shearing/slitting of paper. In this type of work material, abrasive wear is the critical failure mechanism. Failure mechanisms in cold work tooling Due to cyclic mechanical loading and sliding contact between work material and tool surface, the active surfaces of the tool are successively damaged. The destruction of the tool will sooner or later lead to quality problems on the formed parts (out of tolerance or bad surface qualities). The tool has then to be exchanged (total failure), reground or refurbished in some way. This maintenance procedure means production standstill and accordingly loss of productivity. It is therefore very important that the tools can resist the different types of tool failure mechanisms in order to achieve high productivity and economical production. The selection of the right tool steel is thus directly linked to the resistance of the actual tool failure mechanism for the application.

Common cold work failure mechanisms are:

Wear Chipping Plastic deformation Cracking Galling

Method for tool steel selection 1. 2. 3. Identify the dominant failure mechanism(s) Select a tool steel with properties that will overcome this / these failure mechanism(s) Match the steel choice to the length of the production run

Shearing / slitting of austenitic stainless steel

The proper steel selection for this application depends primarily on the type of work material, strength and thickness. The most critical failure mechanisms are adhesive wear, galling, chipping and cracking.

Failure mechanisms in cold work tooling Due to cyclic mechanical loading and sliding contact between work material and tool surface, the active surfaces of the tool are successively damaged. The destruction of the tool will sooner or later lead to quality problems on the formed parts (out of tolerance or bad surface qualities). The tool has then to be exchanged (total failure), reground or refurbished in some way. This maintenance procedure means production standstill and accordingly loss of productivity. It is therefore very important that the tools can resist the different types of tool failure mechanisms in order to achieve high productivity and economical production. The selection of the right tool steel is thus directly linked to the resistance of the actual tool failure mechanism for the application.

Common cold work failure mechanisms are:

Wear Chipping Plastic deformation Cracking Galling

Method for tool steel selection 1. 2. 3. Identify the dominant failure mechanism(s) Select a tool steel with properties that will overcome this / these failure mechanism(s) Match the steel choice to the length of the production run

Shearing / slitting of high strength / ultrahigh strength sheets

The selection of tool material depend on the type of work material, strength and thickness. For high strength sheets, abrasive wear, chipping, cracking and plastic deformations are critical tool problems. For ultrahigh strength sheets, galling also can be a problem. Failure mechanisms in cold work tooling Due to cyclic mechanical loading and sliding contact between work material and tool surface, the active surfaces of the tool are successively damaged. The destruction of the tool will sooner or later lead to quality problems on the formed parts (out of tolerance or bad surface qualities). The tool has then to be exchanged (total failure), reground or refurbished in some way. This maintenance procedure means production standstill and accordingly loss of productivity. It is therefore very important that the tools can resist the different types of tool failure mechanisms in order to achieve high productivity and economical production. The selection of the right tool steel is thus directly linked to the resistance of the actual tool failure mechanism for the application.

Common cold work failure mechanisms are:

Wear Chipping Plastic deformation Cracking Galling

Method for tool steel selection 1. 2. 3. Identify the dominant failure mechanism(s) Select a tool steel with properties that will overcome this / these failure mechanism(s) Match the steel choice to the length of the production run