Tool steels simplified
-
Upload
ryan-rafael -
Category
Documents
-
view
85 -
download
15
description
Transcript of Tool steels simplified
Tool Steel – Simplified
1
Purpose
Purpose of this presentation:
– Give you greater confidence that Mate’s punch and die materials are the best in the industry
– Give you greater confidence that you can sell these advantages
25
20
32
40
50
22
32
25
45
32
0%
20%
40%
60%
80%
100%
120%
0
10
20
30
40
50
60
D2 A18 M2 PD-5 Ultima M4
Mac
hin
eab
ility
Re
lati
ve
Ran
k
Wear Resistance
Toughness
2
Tool Steel Advantages
Which qualities are the Customers looking for ?
– Quality Product• Performing, dependable, reliable, consistent
– Wear Resistance (Adhesive vs. Abrasive)• Resistance to wear from gummy materials – stainless• Resistance to wear from abrasive materials – hot rolled• Provided by hardness level and chemistry (carbide composition)
– Toughness and Good Fatigue Life• Resistance to breakage (fracture) and chipping; impact strength• Opposite of brittleness• Is not same as Hardness
3
Tool Steel Advantages
Which qualities are the Customers looking for ?
– Hardness • Resistance to deformation (compression, indentation)• From 58 to 64 HRc, typical 60-62 HRc
– Price• Must fit the value proposition for the appropriate market
4
– Red Hardness (= Heat Resistance = Anneal Resistance)• Ability to sharpen the product without damaging the material as well as
being able to coat it (heated operations)
Tool Steel Simplified
Basic Structure
Matrix (Base):
• The mortar that holds the road together
• Matrix compositions can be altered to enhance toughness, hardness, heat resistance, corrosion resistance
Carbides:
•Offer resistance to abrasion similar to cobble stones
•Carbide volume and composition can be altered to offer enhanced wear resistance usually at the expense of toughness and fabricability/machinability
5
Tool Steel Simplified
• Carbides consists of Carbon (0.5 to +2%) in combination with alloying elements
• Cr (Chromium)• Mo (Molybdenum)• Si (Silicium)• W (Tungsten)• V (Vanadium)
• The carbides are harder than the matrix and provide the wear resistance
6
Tool Steel Simplified
• The carbides are formed during the fabrication process and can be from 5 to 20% of the tool steel (“alloy content” or “carbide content”)
• Amount and type of carbides are different in different tool steel grades A2 – D2 – M2
• More (hard) carbides give more Wear Resistance, but less Toughness (more brittle) – “trade off”
7
Tool Steel Simplified
Correct chemistry is important
•A minimum amount of Carbon is needed to • form carbides during the manufacturing process, and • harden sufficiently during the heat treatment process
•The total carbide content (in quality and quantity) is important for the Wear Resistance,
Vanadium (V) carbides are the hardest and contribute most M2 steel contains 2% Vanadium M4 steel contains 4% Vanadium
•Vanadium: forms very wear resistant carbides, but it also can imbrittle the material. Eexpensive.
8
Tool Steel Simplified
Correct chemistry is important
•Chromium (Cr): causes more uniform hardness while forming carbides and increasing the strength of the material matrix. Is least effective for the Wear Resistance. Also leads to size instability in sufficient quantity (D2).
•Silicon (Si): helps to increase toughness and strength when used with other alloys.
•Tungsten (W): dramatic impact on hardness and resistance to heat effects in higher quantity (HSS materials). Expensive.
•Molybdenum (Mo): helps to increase hardenability and red-hardness when present with other alloys like chrome and manganese. Also forms good wearing carbides.
9
Tool Steel Simplified
The higher the Wear Resistance …
… the lower the Toughness.
10
- At a similar hardness, greater amount of carbides will show better wear resistance
- The higher the hardness for the same carbide, the lower the toughness
Tool Steel Simplified
11
Notes:-The total Carbide volume determines the wear resistance (abrasive and adhesive).-“High Speed Steel” starts at 3-4% Tungsten, Molybdenum is important too-Wilson’s proprietary A18 is A18 plus a little Tungsten, not enough for HSS
Conventional Tool Steels
HSSHSS
Results and Comparisons
To
ug
hn
ess
12
Note: -M4 is not M4PM!-Amada still uses a lot of D2 (e.g. in slitting blades)-DuraSteel has more Toughness and Abrasive Wear Resistance than M2, less Adhesive Wear Resistance-in general, dies need more toughness (cantiliver effect), punches more wear resistance
P20 17-4
17-4 H11,H13
S2, S5
S7
W1
L2 420, L6
H14, H21
H19 3V 9V
H24 3V 9V
L2 L3 A2, H26
M4
O1 T1, M2
T2
T4 D2, M3
M4, T15
10V
T5 D4 A7, T15
Histar40
A18Cruwear
Vertex
Conventional Tool Steels
Abrasive Wear Resistance
Tool Steel Simplified
13
Note: -Wear Resistance = Abrasive + Adhesive
How is a Tool Steel made ?
Manufacturing Process (conventional way)
1. Desired chemical composition is melted in large batches
How is a Tool Steel made ?
Manufacturing Process (conventional way)
1. Desired chemical composition is melted in large batches
2. Poured into “ingot molds” to solidify
• Carbides are now formed
• Slow solidification process will cause Carbides to form ‘interconnected’ segregation networks
• More carbides give more Wear Resistance and less Toughness, but high volumes of carbides (“high alloy steels”) result in more segregation (= non-uniform microstructure)
15
How is a Tool Steel made ?
Manufacturing Process (conventional way)
1. Desired chemical composition is melted in large batches
2. Poured into “ingot molds” to solidify
• Carbides are now formed
• Slow solidification process will cause Carbides to form ‘interconnected’ segregation networks
• More carbides give more Wear Resistance and less Toughness, but high volumes of carbides (“high alloy steels”) result in more segregation (= non-uniform microstructure)
3. Rolled or forged into bars
16
Manufacturing Process (conventional) (Contd.)
2 fundamental segregation problems:
o More carbides give more WR, but high volumes of carbides (high alloy steels) in a non-uniform structure due to segregation makes the tool difficult to manufacture (grinding problems; chipping)
o The segregations get elongated during rolling or forging, get directionally oriented and reduce toughness; grinding problems; chipping risk
For better tool steels, more carbide content is needed (especially higher Vanadium contents), but this imbrittles the tool steel (less toughness)
=> Different process needed ! 17
How is a Tool Steel made ?
Non-uniform Carbide size and distribution
(> 50 microns)
Crucible Powder Metallurgy (CPM)
Especially designed for high Vanadium content alloys
1. Desired chemical composition is melted
2. Rapid solidification into fine droplets (“powder”)• 2-4 microns; segregation is virtually eliminated
3. Powder is consolidated• Powder particles are bounded together under high
pressure
4. Forged or rolled into bars
18
How is a Tool Steel made ?
100
How Is How Is Particle Metallurgy Particle Metallurgy Different From Traditional Different From Traditional Ingot Metallurgy?Ingot Metallurgy?
Induction Melting /Gas Atomizing
AOD Melting
Hot IsostaticPressing (HIP)
Ingot Casting
Rapidly SolidifiedSpherical Powder
Alloy Segregationat Billet Conventional M4
Microstructure
CPM M4Microstructure
Ingot Metallurgy
CPM Processing
(as-HIP or forged) 19
Tool Steel Simplified
21
CPM vs. Conventional
Powder Metalurgy allows higher volumes of Carbides, without segregation problems, even increasing Toughness
Results and Comparisons
To
ug
hn
ess
Abrasive Wear Resistance
22
P20 17-4
17-4 H11,H13
S2, S5
S7
W1
L2 420, L6
H14, H21
H19 3V 9V
H24 3V 9V
L2 L3 A2, H26
M4
O1 T1, M2
T2
T4 D2, M3
M4, T15
10V
T5 D4 A7, T15
Histar40
A18Cruwear
MPM82
M4PM
$$$
Vertex
Vertex- Powder
PD-5
Note: -DuraSteel has more Toughness and Abrasive Wear Resistance than M2, less Adhesive Wear Resistance-Amada still uses a lot of D2-MPM82 is powder Cruwear (Durasteel)-Dies need more toughness (cantiliver), punches more wear resistance
Powder Metals shift the line!
Powder Metals shift the line!
Tool Steel Simplified
23
Notes:-The total Carbide volume determines the Wear Resistance (abrasive and adhesive).-“High Speed Steel” starts at 3-4% Tungsten, Molybdenum is important too- ‘M2’ and ‘M4’ mean high Molybdenum content and 2% or 4% Vanadium-Wilson’s proprietary A18 is A18 plus a little Tungsten, this not really HSS
Tool Steel Simplified
24
Note: -Wear Resistance = Abrasive + Adhesive-PD-5 is a grade of Wilson’s Ultima-Vertex (Powder) is used by Pass
Tool Steel Advantages
25
Benefits of Power Metallurgy:
Comparison of Wear Development on Conventional (left) and P/M (right) Tool Steel
Tool Steel Advantages
Summary of Qualities Customers Look For:
– Quality Product– Wear Resistance (Adhesive vs. Abrasive)– Toughness and Good Fatigue Life– Hardness– Red Hardness– Price
26
Tool Steel Advantages
What does Mate Do?
– Mate optimizes toughness and wear for the appropriate application and market price
– Not all punching environments are the same
• Dies generally favor toughness (inherent to the shearing of the material more closely matching the punch size)
• Punches and dies in a less challenging environment favor wear (Trumpf and Thick Turret)
• Punches and dies in a more challenging application favor toughness (Typically Thin Turret and 112/114)
• Price sensitive markets prefer more economical materials (Thin Turret and 112/114)
27
Tool Steel Advantages
What does Mate Do?
– Mate controls the quality better than other tooling suppliers
• Mate has rigorous standards for each tool steel supplier
• We don’t shop for the cheapest material – Lower grade tool steels become a commodity at low price
• We know the best mills
• Mate accepts steel only from certified sources
• Tested on manufacturability, segregation, inclusions
• Mate uses world class heat treaters and heat treatment processes
28
Tool Steel Simplified
How Does Mate Achieve These Qualities:
• Control the Supply Chain– Audit materials against industry standards for a specific material
– Test the machining of the material for any change in machinability
– Independently section and test materials with an independent laboratory
• Control the Chemistry of the Material– Amount and Quality of Carbide Formation (Wear/toughness)
– Hardness (Wear/toughness/strength)
– Resistance to Heat (Red hardness)
– Size Stability
– Price (some elements cost much more than others)
29
Tool Steel Simplified
How To Achieve These Qualities
• Control How the Material is Created
– Controlling ingot sizes and yield %• Smaller sizes usually have less contamination and piping• Lower yield % means leaving the slag behind
– Controlling alloy distribution• Working (hitting/rolling/reducing) the material into smaller
billets• Re-melting the material• Particle Metallurgy
30
Tool Steel Simplified
Tool steel bars
Machining processes
Soft Blanks
Hardening
Hard blanks
Machining processes
Stock
Point Finishing
if required: Maxima Coating or Nitriding
Finished tool
• Control How the Material is Heat Treated
Heat Treatment
31
Tool Steel Simplified
• Control How the Material is Heat Treated (Creation of the Microstructure)
–Controls Properties of Hardness, Size Stability, and Carbide Formation for Wear Resistance
–Is Described by this Process:
• Preheating + Heating to the Austenitizing T° and holding it for a set duration- Creates uniform micro structure ”AUSTENITE””AUSTENITE”
• Quickly reducing the temperature (Quench Rate)- Makes it strong, but brittle and unstable ”UNTEMPERED MARTENSITE””UNTEMPERED MARTENSITE”
• Raising the temperature (Tempering Temperature) and repeating as necessary (Number of Tempers)
- A little less strong, but much tougher now ”TEMPERED MARTENSITE””TEMPERED MARTENSITE”
32
Tool Steel Simplified
Heat Treatment Process – low alloy steels
(Degrees Fahrenheit)
(Air or Oil)
(Hardened blank willneed grinding to size)
33
Tool Steel Simplified
Heat Treatment Process – high alloy steels
(Degrees Fahrenheit)
34
Tool Steel Simplified
Heat Treatment Process – high alloy steels
(Degrees Fahrenheit)
(Maxima not possible on Maxima not possible on low alloy steels)low alloy steels)
35
Tool Steel Simplified
Summary:
– Quality, Chemistry, Processing, and Heat Treatment are All Important!
– Trade off between Wear and Toughness
– Powder metals can help this trade off but adds costs
36
Tool Steels Landscape
37
M4PM lasts longer !!!
Trumpf style M4PM Punches vs Competitors
38
M4PM lasts longer !!!Notes:
-Trumpf uses HSS (similar to M2) in Europe
-Wilson std. is A18; 2-4-1 is PD-5
-Pass uses Vertex (DC53) Powder
Thick Turret M4PM Punches vs Competitors
39
Notes:
-Wilson std. is A18; EXP is PD-5
-Pass uses Vertex (DC53) (non powder)
-Amada still uses some D2
MPM4 lasts longest !!!!
Tool Steel Advantages
Summary:
– Mate offers the best quality
– Mate offers the best characteristics for the application and market conditions
– Mate monitors changing market conditions (Competitive Analysis Program)
– Mate researches better materials and alternate tooling approaches (bimetal, insert products, etc.)
40
Tool Steel Advantages
41
Benefits of Powder Metallurgy Tools for End Users
• Very high consistency• Optimum tooling reliability• Cost recoverable through improved performance
– Increased wear resistance
– Increased toughness
• Improved machine up-time– Less frequent sharpening
– Less fall-outs due to breakage
“The Power of Powder”
Tool Steel Advantages
Group exercise:
- Where do we use M4PM tool steel ?
42
Size 0A/0B : M4Size 1 – std & QL : M2 M4 upgradeSize 2 – std & QLNEXT – complete lineMultitool 5 and 10 punches LongLife punch and die blades
Slitting blades Ultra A and B (optional)
See presentation
Trumpf:
Thick Turret:
Salvagnini:
Tool Steel – Simplified
Thank you !