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wdx2501m.pdf

EUROPEAN MATERIAL PROPERTIESFOR HIGH STRENGTH STEEL AND MILD STEEL.

For Application see "Limit Curve W-DX25-40M Page 5"

Mild Steel

MS4MS3MS2MS1

MS4+EZ100MS3+EZ100MS2+EZ100MS1+EZ100MS4+Z100MS3+Z100MS2+Z100MS1+Z100MS4+IZ110MS3+IZ110MS2+IZ110MS1+IZ110

Short HandMaterial Code

Tensile Strength Rm [N/mm²]

WSS-M1A345-A4WSS-M1A345-A3WSS-M1A345-A2WSS-M1A345-A1WSS-M1A345-A4WSS-M1A345-A3WSS-M1A345-A2WSS-M1A345-A1WSS-M1A345-A4WSS-M1A345-A3WSS-M1A345-A2WSS-M1A345-A1WSS-M1A345-A4WSS-M1A345-A3WSS-M1A345-A2WSS-M1A345-A1

Ford Specification

270 - 330270 - 330270 - 340270 - 350270 - 330270 - 330270 - 340270 - 350270 - 320270 - 330270 - 350270 - 400270 - 320270 - 330270 - 350270 - 400

High Strength SteelTensile Strength Rm [N/mm²]

350 - 430380 - 480410 - 510460 - 560480 - 590340 - 400380 - 440400 - 480300 - 350340 - 400370 - 430400 - 480350 - 410300 - 380320 - 400340 - 420450 - 530500 - 600600 - 700780 - 900310 - 390340 - 400350 - 410380 - 440

WSS-M1A347-A1WSS-M1A347-A2WSS-M1A347-A3WSS-M1A347-A4WSS-M1A347-A5WSS-M1A341-A1WSS-M1A341-A2

-WSS-M1A341-A3WSS-M1A341-A4WSS-M1A341-A5WSS-M1A341-A6WSS-M1A341-A7

WSS-M1A341-A10--

WSS-M1A348-A1WSS-M1A348-A3WSS-M1A348-A5

--

WSS-M1A341-A8WSS-M1A341-A1WSS-M1A341-A2

HSLA260HSLA300HSLA340HSLA380HSLA420

RP220RP260RP300BH180BH220BH260BH300

BHZ260IS220IS260IS300DP450DP500DP600DP780IF160IF180IF220IF260

Ford SpecificationShort Hand

Material Code

ALWAYS USE MAXIMUM VALUE FOR LIMIT CURVE ON PAGE 5

PRINTED COPY ISUNCONTROLLED

DIE DESIGN ANDCONSTRUCTION SPECIFICATIONS

STAMPING - EUROPE

W-DX25-40MPAGE: 4SEP-2005

STAMPING - EUROPE DIE MATERIALS

For Draw Dies use Inserts Material: 1.2382 (1.2379)

( H and CVD coated)

In special cases GP4M ( H )

Change Material

for Upper Trim Steelfrom 1.2333 into GP4M ( H )

for Piercing Punchesfrom 1.3343 into Vanadis 4-----------------------------------------For Lower Trim Inserts use

Material: Vanadis 4 / PMDM4 ( H )

4,0

3,5

3,0

2,5

2,0

1,5

1,0

0,5

0,0

350

400

450

500

550

600

650

700

750

800

850

900

950

1000

Tensile Strength Rm [N/mm²]

Mat

eria

l Thi

ckne

ss [m

m]

LIMIT CURVES

If Thickness of used Panel Material is above Limit Curvetake following actions:

Change Material

for Trim Bucksfrom 1.7140 into 1.2333 ( FH / IH )

for Upper Trim Steelfrom 1.2320 into 1.2333 ( FH / IH )

------------------------------------------For Cutting and Flange Steels

back up is necessary.

Always use maximum Value from Table on Page 4


DIE DESIGN ANDCONSTRUCTION SPECIFICATIONS

STAMPING - EUROPE

W-DX25-40MPAGE: 5FEB -2006

STAMPING - EUROPE DIE MATERIALS

AR

EA

CH

ANG

ED

WORLDWIDE DIE DESIGN ANDCONSTRUCTION SPECIFICATIONS

VEHICLE OPERATIONS

EUROPE ONLY

DIE MATERIALS

DIN BSI

BS 2789GRADE420/12

BS 2789GRADE600/3

BY 1452GRADE 220

EQUIVALENTSTANDARD DESIGNATION

1.2320

DATESEPT. 2005

1.2382

1.7140(SG-7)

EN-JS 1060(GGG-60)

EN-JS 1030(GGG-40)

TOOL STEELCASTING

G 60CrMoV10-7

G 47CrMn6

GX155CrVMo 12-1

2 CARBON14 CHROMETOOL STEEL

CASTING

0,5 CARBON1,5 CHROMETOOL STEEL

CASTING

SPHEROIDALGRAPHITECAST IRON

SPHEROIDALGRAPHITECAST IRON

DINEN 1563

DINEN 1563

EN-JS 1050(GGG-50)

EN-JS 2070(GGG-70L)

EN-JL 1040 (GG-25)

EN-JL 2060(EGG-25)

MAT. No.DESIGNATION

INSTOCK LIST

ALLOYEDSPHEROIDAL

GRAPHITECAST IRON

CAST IRON

FLAME-HARDENINGCAST IRON

CAST IRON

DINEN 1563

DINEN 1563

DINEN 1561

DINEN 1561

SEL. No. MATERIALDESCRIPTION

LOWER DRAW DIES.PUNCHES AND BLANK-HOLDERS FOR CRITICALDRAW PARTS WHEREHEAVY WEAR IS EXCEPTED;

FOR TRI-AXIS-DIES IN PRINCIPAL CHECK BACK WITH DIE DESIGN SYSTEMDEPARTMENT

W-DX25-40M

PADS AND STRIPPERSWITH THIN SECTIONS.

LARGE PUNCHES ANDDIES FOR RESTRIKEDIES.

FEMALE FLANGE STEELSFOR MATERIAL "ABOVE LIMIT CURVE " OR FLANGE DEPTH ABOVE 25 mm. INSERTS FOR DRAW DIES AND BARS FOR DRAW PANEL LIFTER.

TRIM STEEL FOR MATERIAL"BELOW LIMIT CURVE"FLANGE STEEL WITHSTRAIGHT FLANGE LINE ANDRESTRIKE DIES WITHOUT RELATIVE MOVEMENT FOR MATERIAL "BELOW LIMIT CURVE ".

ONE PIECE PUNCHESFOR TRIM DIES ANDLOWER- AND CUTTINGSTEELS FOR MATERIAL "BELOW LIMIT CURVE ".

250 MAX.HARDENED

ANDTEMPERED

IH54-60

SECTIONPAGE 6

285 MAX.

250 MAX.HARDENED

ANDTEMPERED

FH/IH54-56

IH/H58-62

FH/IH50-54

AR

EA

CH

AN

GED


APPLICATION

DRIVERS AND CAMWORKING SLIDESWITHOUT WEAR PLATES.LOWER AND UPPER DIES. PADS AND STRIPPERS WITH THIN SECTIONS.

PUNCHES AND BLANK-HOLDER RINGS FORDRAW DIES.

LOWER DIES, UPPER DIES, BUCKS AND PADS WITH THICK SECTIONS,BLANKHOLER PLATES,DRIVERS AND CAMWORKING SLIDES WITHWEAR PLATES.

IH54-58

FH/IH50-54

HARDNESSAS DE-

LIVEREDBRINELL

USUALHARDNESSROCKWELL

C

W-DX

MATERIALS AND THEIR USAGECASTINGS

*

* FOR LIMIT CURVE SEE W-DX25-40M Page 5

*

*

WORLDWIDE DIE DESIGN ANDCONSTRUCTION SPECIFICATIONS

VEHICLE OPERATIONS

EUROPE ONLY

DIE MATERIALS

DIN BSI


MATERIALS AND THEIR USAGE

DATESEPT. 2005

MAT. No.DESIGNATION

INSTOCK LIST

1.2333 G 59CrMoV18 - 5

TOOL STEELCASTING

SEL. No. MATERIALDESCRIPTION

W-DX25-40MSECTIONPAGE 7

ONE PIECE TRIM BUCKS IN LOWER TRIM DIES FOR MATERIAL "ABOVE LIMIT CURVE". FOR DIFFICULT TRIM CONDITIONS INDEPENDENT OF THE MATERIAL THICKNESS.


APPLICATIONHARDNESS

AS DE-LIVEREDBRINELL


C

250 - 290HARDENED

AND TEMPERED

FH / IH56 - 60

W-DX

CASTINGS, ( Continuing from Page 6 ):

1) MATERIALS (BARS AND FORGINGS, TUNGSTEN CARBIDE)


C

HARDNESSAS DE-

LIVEREDBRINELL

CH56 - 60

H56 - 63

BASE-; UPPER AND ADAPTER PLATES; PADS AND STRIPPERS, WELD CONSTRUCTIONS.

WEAR PLATES

AIR PINS, BALANCE PINS, RETAINER BOLTS, SIDE LOCK PINS, ETC.

APPLICATION

BACKING PLATES

MATERIALDESCRIPTION

SEL. No.

DIN 17100

C 15

DIN17350

90MnCrV8

BLACK MILD STEEL

CASE HARDEN,MILD STEEL

WEAR RESIST. STEEL BLACK

RSt-37-2

MAT. No.DESIGNATION

INSTOCK LIST

1.0401

1.0038

DIN 17210

1.0503.01

OIL HARDENING TOOL STEEL1.2842


BS 970PART 1

1983055M15

BS 4659BO 2

DIN BSI

1.0037 St-37-2BRIGHT MILD STEEL

DIN 1652

BS 970PART 1

1983080M50

C 45 DIN 17210

BS 970PART 1

1983080M15

1.0503 WEAR RESIST. STEEL BRIGHT

C 45 K DIN 1652

1.23792 CARBON

12 CHROME4 VANADIUM

X155CrVMo12-1 DIN17350

BS 4659BD 2

FH / IH / H58 - 62

CUTTING STEELS, FORM STEELS FOR FLANGE AND RESTRIKE DIES, INSERTS IN DRAW DIES.

GT 20 - HP TUNGSTENCARBIDE

FLANGE SECTIONSFOR SPIDERS

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STOCK LIST DETAILS.

THE TYPE OF HARDENING OF THE DIE PART IS REQUIRED IN THE REMARKSCOLUMN OF THE STOCK LIST IN THE FOLLOWING ABBREVIATED FORM: -

FH - FLAME HARDEN

H - HARDEN THROUGHOUT

ALL OTHER HEAT TREATMENTS SUCH AS STRESS RELIEVING,NITRIDING, ETC. MUST BE WRITTEN IN FULL.

MATERIAL IDENTIFICATION.

BEFORE A DIE IS HEAT TREATED IT MUST BE STAMPED WITH MATERIALIDENTIFICATION OF THE MATERIAL ACTUALLY USED E.G. 1.2379, 1.2842, C-15.

THIS IDENTIFICATION TO BE STAMPED BESIDES THE USUAL IDENTIFICATION(DIE NO.)

THE DESIGNATION MUST BE STAMPED OR CAST ON A SURFACE NOTSUBSEQUENTLY REWORKED.

CH OR EH - CASE HARDEN

EUROPE ONLY

10 DEC. 1997

IH - INDUCTION HARDEN


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CASTING TEST PARTS

DIMENSIONS OF THE TESTPARTS.

EUROPE ONLY

150

15

M20

15LO=5XD=70

D=14O/

CAST(EN-JS 2070)

125

CAST (EN-JS 2070)

MATERIAL FORPOLISH SECTIONAND ANALYSIS.

50

35

50

JAN. 200112

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HARDENING

1 FLAME HARDENING

INTRODUCTION

1.1 SCOPE

1.2 APPLICATION

1.3 COMPARISON BETWEEN FLAME HARDENING & THROUGH HARDENING

2 PROCESS

2.1 PARTS TO BE HARDENED

2.2 METHOD OF HARDENING 2.21 STEEL 1.23792.22 IH CAST IRON EN-JL 2060 (EGG-25) 2.23 SPHERIODAL GRAPHITE CAST IRON EN-JS 1060 (GGG-60)

2.25 CAST STEEL 1.7140 (SG-7) 2.26 SPHERIODAL GRAPHITE CAST IRON EN-JS 2070 (GGG-70L) 2.27 HIGH STRENGTH COLD TOOL WORK STEEL Nr.: 1.2333 ("BOEHLER CARMO"&"DE-AMO")2.28 CAST IRON (GG-25Cr)

2.3 SELECTION OF BURNERS

2.4 DEPARTMENTS/SUPPLIERS CARRYING OUT THE WORK

2.5 SAFETY PRECAUTIONS

2.6 HEAT TREATMENT DURING THE MACHINING PHASE

3 THROUGH HARDENING 3.1 MATERIAL DESIGNATION 1.2842

4 IONITRIDING

5 CVD-COATING

STOCKLIST DETAILS

EUROPE ONLY

15SEPT. 2001

3.2 MATERIAL DESIGNATION 1.2379

2.24 CAST STEEL 1.2320

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1 FLAME HARDENING

INTRODUCTION

SCOPE

FLAME HARDENING IS A METHOD OF PRODUCING SURFACE HARDNESS ON SUITABLESTEELS OR IRON CASTINGS. THIS IS ACHIEVED ON STEELS BY PRE-HEATING THE FINISH MACHINED PART IN A HT FURNACE AND BY HEATING FOR A SHORT PERIOD WITH SUBSEQUENT IMMEDIATE QUENCHING IN A STREAM OF AIR OR COMPRESSEDAIR. ON CASTINGS, THE FINISHED MACHINED PART IS HEATED ON THE EDGES TO BE HARDENED AND SUBSEQUENTLY WATER QUENCHED. THE FLAME TO BE APPLIED FOR THIS IS PRODUCED BY A FUEL GAS/OXYGEN MIXTURE. PROPANE OR METHANE ISUSED AS FUEL GAS.

THERE ARE SEVERAL TYPES OF PROCESSES WHICH DIFFER IN TYPE OF RELATIVEMOTION BETWEEN PART AND BURNER (HEAD). THE PREFERRED PROCESS FOR DIE MANUFACTURE HAS THE WORKPIECE STATIONARY. THE BURNER IS PASSED MANUALLY ACROSS THE SURFACE OR EDGES TO BE HARDENED. BURNER STRENGTH AND FEED HAVE TO BE WITHIN THE APPROPRIATE RELATIONSHIP TO ACHIEVE CONSISTANTHARDENING.

APPLICATION

DRAW DIE AND FORMING TOOL AREAS SUBJECT TO WEAR OR COMPRESSION STRESSARE FLAME HARDENED AT THE EDGES AND RADII. LITTLE BENEFIT IS OBTAINED BY FLAME HARDENING WHOLE AREAS OF THESE TOOLS, BECAUSE THESE AREASSCARCELY SUFFER WEAR, AND DIFFICULTIES ARISE ON REWORKING THE TOOLDURING PRODUCTION.

CRITICAL DRAW CONDITIONS MAY HOWEVER NECESSITATE FLAME HARDENING OFWHOLE BLANKHOLDER AREAS. THE DECISION WHETHER BLANKHOLDER AREAS ARE FLAME HARDENED OR NOT IS BASED ON EXPERIENCE AND WILL BE MADE BY THEPLANT EFFECTED.

CHARACTERLINES ON DRAW PUNCHES AND LOWER DRAW DIES ARE TO BE FLAMEHARDENED IN ALL CASES.

THE EDGES AND RADII TO BE FLAME HARDENED HAVE TO BE IDENTIFIED BY THE TOOLDESIGNER ON A REDUCED REPRESENTATION OF THE PART (SCALE 1:5) ON THE DIEDRAWING.

SHOULD IT APPEAR DURING MANUFACTURE OF THE DIE THAT FURTHER EDGES NOT SOINDICATED BY DIE DESIGN MUST BE FLAME HARDENED, TOOL ROOM WILL PROCEED INACCORDANCE WITH GENERAL STATEMENTS IN FLAME HARDENING EDGES.

1.1

1.2

EUROPE ONLY

17DEC.1996


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Section A-A

Section B-B

A

A

B

B

EXAMPLES OF APPLICATION:

xxx HARDEN STYLING LINES

EUROPE ONLY

19APRIL 2001

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2.22 IH CAST IRON EN-JL 2060 (EGG-25)

PREHEATING: NONE

HARDENING: THE FINISHED MACHINE WORKPIECE IS HEATED AT THEEDGES OR SURFACES TO BE HARDENED TO ABOUT 840 C.o

WATER FLOWS THROUGH NOZZLES PLACED IMMEDIATELYBEHIND THE FLAME AT THE BURNER, AND QUENCHES THEHEATED EDGE AS IT PROGRESSES.

THE WATER SHALL HAVE A TEMPERATURE OF 20-30 C.o

TEMPERING: TEMPERING RESULTS FROM THE RESIDUAL HEAT (EMITTED)FROM WITHIN THE PART. THIS SHOULD PRODUCE A HARD- NESS OF 370 - 450 HB. USE A SUITABLE HARDNESS TESTING INSTRUMENT.

EUROPE ONLY

JAN. 2001 21

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2.23 SPHEROIDAL GRAPHITE CAST IRON EN-JS 1060 (GGG-60)

PREHEATING: NONE

HARDENING: THE FINISHED MACHINED WORKPIECE IS HEATED AT THEEDGES OR SURFACES TO BE HARDENED TO ABOUT 960 C.o

WATER FLOWS THROUGH NOZZLES PLACED IMMEDIATELYBEHIND THE FLAME AT THE BURNER, AND QUENCHES THEHEATED EDGE AS IT PROGRESSES.

THE WATER SHALL HAVE A TEMPERATURE OF 20 - 30 C.o

TEMPERING: TEMPERING RESULTS FROM THE RESIDUAL HEAT (EMITTED)FROM WITHIN THE PART. THIS SHOULD PRODUCE A HARD- NESS OF 500 - 650 HB. USE A SUITABLE HARDNESS TESTING INSTRUMENT.

EUROPE ONLY

JAN. 200122

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23SEPT. 2001

EUROPE ONLY

DELIVERING CONDITIONS:

PREHEATING:

HARDENING:

TEMPERING:

THROUGH HARDENING:

2.24 CAST STEEL 1.2320

ANNEALED MAX. 250HBHARDENED AND TEMPERED 32-34 HRC

TO PREVENT STRESSES, THE FINISHED WORKPIECE TO BEHARDENED IS PREHEATED TO 650 C BY THE BURNER.o

THE WORKPIECE IS HEATED AT THE EDGE TO BE HARDENEDBY THE BURNER TO ABOUT 900 -920 C WORK WITH REDUCEDo o

FLAME, I.E. WITH EXCESS GAS AND LONG FLAME CONE.APPLY FLAME AT ABOUT 15mm FROM THE EDGE TO BE HARDENED

SUBSEQUENTLY QUENCHED IN STILL AIR OR DRY COMPRESSED AIR.

TEMPERING RESULTS FROM THE RESIDUAL HEAT (EMITTED) FROMWITHIN THE PART. THIS SHOULD PRODUCE A HARDNESS OF 50-60 HRC. USE A SUITABLE HARDNESS TESTING INSTRUMENT.

HARDENED TEMPERATURE 900 -920 C.o o

QUENCHING MEDIUM AIR/OIL.ANNEALING SEE DIAGRAM BELOW.HARDNESS 50-60 HRC.

AND PASS IT EVENLY ACROSS THE WORKPIECE. THE WORKPIECE IS

1.2320900 C/AIRo

0 100 200 300 400 500 60045

50

55

60

65

ANNEALING TEMPERATURE Co

HARDNESS (HRC)

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HARDENING:

TEMPERING:

HRC

HARDNESS

48

0

DELIVERING CONDITIONS:

2.25 SPECIAL CAST STEEL 1.7140 (SG-7)

ANNEALED MAX. 250 HBHARDENED AND TEMPERED 32-34 HRC


THE WORKPIECE IS HEATED AT THE EDGE TO BE HARDENEDBY THE BURNER TO ABOUT 850 - 860 C. WORK WITH RE- o o

DUCED FLAME, I.E. WITH EXCESS GAS AND LONG FLAMECONE. APPLY FLAME AT ABOUT 15 mm FROM THE EDGE TO BE HARDENED AND PASS IT EVENLY ACROSS THE WORKPIECE.THE WORKPIECE IS SUBSEQUENTLY QUENCHED IN STILL AIROR DRY COMPRESSED AIR.

TEMPERING RESULTS FROM THE RESIDUAL HEAT (EMITTED)FROM WITHIN THE PART. THIS SHOULD PRODUCE A HARD- NESS OF 54-56 HRC. USE A SUITABLE HARDNESS TESTING INSTRUMENT.

3.0 3.5 4.0 4.50.5 1.5 2.0 2.5

62

60

58

56

54

52

50

PREHEATING:

1.0

HARDNESS DEPTH IN MM

EUROPE ONLY

SEPT. 200124

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2.26 SPEROIDAL GRAPHITE CAST IRON EN-JS 2070 (GGG-70L)

DELIVERING CONDITION: 210 - 260 HB

PREHEATING: NONE

HARDENING : THE FINISH MACHINED WORKPIECE IS HEATED AT THE EDGES OR SURFACES TO BE HARDENED TO ABOUT 820 - 840 C.o o

WATER FLOWS THROUGH NOZZLES PLACED IMMEDIATELY BEHIND THE FLAME OF THE BURNER AND QUENCHES THE HEATED EDGE AS IT PROGRESSES.

THE WATER SHALL HAVE A TEMPERATURE OF 20 - 30 C.o

WATER-COOLING DOWN TO ROOM TEMPERATURE.

HARDNESS 54 - 58 HRc.

TEMPERING : NO TEMPERING

EUROPE ONLY

25JAN. 2001

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2.27 HIGH-STRENGTH COLD TOOL WORK STEEL 1.2333

THE USE OF 1.2333 TOOL STEEL IN PRESS DIES

APPLICATION

1. FOR ONE-PIECE TRIM BUCKS FOR MATERIAL THICKNESS 1,5 OR MORE.

2. FOR DIFFICULT TRIM CONDITIONS,INDEPENDENT OF THE MATERIAL THICKNESS.

DELIVERY CONDITION

PRE-HARDENED TO 250-290 HB. THIS CORRESPONDS TO A TENSILE STRENGTH OF 850-980 N/mm2 THE STEEL MUST BE THROUGH (PENETRATION) HARDENABLE.

TEMPERING GRAPH


o

IN GENERAL THE STEEL WILL BE USED IN LOWER TRIM DIES:

CORE HARDNESS (HRC) RETAINED.AUSTENITE (%)

40

45

50

55

60

65

0 100 200 300 400 500 600

10

20

30

40

50

TEMPERING TEMPERATURE C (2h+2h)

WELDING RECOMMENDATION

TA=960 C

SMALL WELDINGS (REPAIRS) CAN BE CARRIED OUT WITHOUT PREHEATING ON SOFT OR

HARDENED WORK PIECES

FOR LARGE WELDINGS THE FOLLOWING TREATMENT IS RECOMMENDED:

PRE-HEAT THE CAST STEEL TO 200 -250 C AND MAINTAIN THIS TEMPERATURE DURING THE COMPLETE WELDING PROCESS

AFTER WELDING ALLOW THE CAST STEEL TO COOL SLOWLY TO 70 C

TEMPERING IS CARRIED OUT AT 20 C BELOW THE PREHEATING TEMPERATURE

-

-

-

RETAINED.AUSTENITE

o

o o

o

o

EUROPE ONLY

SEPT. 200126

FLAME HARDENING OR INDUCTION HARDENING;HARDNESS 58

SURFACE-HARDENING

PREHEATING:

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FOR THE WELDED BASE BUILD UP, A SOFT WELD ELECTRODE OF THE 29/9 TYPE

SHOULD BE USED (29% Cr,9% Ni)

FOR THE HARD OUTER SURFACE A WELD ELECTRODE, EXAMPLE:UTP67 S OR CASTOLIN 2R

CAST DESIGN AND WEIGHT

MAX. CASTING WEIGHT IS 1500 Kg. THE CASTING SHOULD BE DESIGNED

ACCORDING TO 1.7140 (SG-7) STANDARD

CVD COATING IS NOT RECOMMENDED

SHOULD BE USED

EUROPE ONLY

27APRIL 2001

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BASE HARDNESS,DELIVERY CONDITION : 190-230 HB 30

FLAME HARDENING OR INDUCTION HARDENING IS POSSIBLE

ATTAINABLE SURFACE HARDNESS >45 HRC

HARDNESS

Rm = 250 N/mm2 MIN.

TENSILE STRENGTH (DIN 1691)

IN GENERAL FOR DRAW DIES (MATRIX,BLANKHOLDER AND PUNCH)

FOR LOW VOLUME PRODUCTION.

NOT FOR CRITICAL DRAW PANELS WHERE HIGH WEAR IS EXPECTED.

APPLICATION

SPECIFICATION GG25 Cr

2.28 CAST IRON

EUROPE ONLY

SEPT. 200128

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EUROPE ONLY

29DEC. 1996

2.3 SELECTION OF BURNERS

FOR CUTTING STEELS, THE SINGLE BURNER SIMILAR TO WELDING TORCH, IS SUITABLE.FOR EDGES AND RADII ON DRAW DIES AND LIKE, A MULTI FLAME BURNER IS USED.HERE ARE SOME EXAMPLES OF BURNERS AS ILLUSTRATED, FOR VARIOUS PARTS.


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2.4 DEPARTMENTS/SUPPLIERS CARRYING OUT THE WORK

ALL CUTTING STEELS, FLANGING STEELS AND RESTRIKING STEELS AREHARDENED BY THE MANUFACTURER OF THE DIE.

ALL CHARACTER LINES AND DRAW RADII ON DRAW PUNCHES AND LOWERDRAW DIES AS WELL AS DRAW BEADS ARE FLAME HARDENED BY THE PRO-DUCTION PLANT.

2.5 SAFETY PRECAUTIONS

SAFETY REGULATIONS FOR CUTTING AND WELDING MUST BE OBSERVED.

EUROPE ONLY

DEC. 199630


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HEAT TREATMENTDURING THE MACHINE PHASE

MATERIAL NO: 1.2379

TRIMMING STEELS, FLANGING STEELS AND INSERTS OF SIMPLE SHAPE AND NOTLONGER THAN 450 mm MAY BE MADE TO THE FINAL DIMENSIONS (OR WITH GRINDINGALLOWANCE) AND THEN BE FLAME OR THROUGH HARDENED.

IN ORDER TO AVOID WARPING DURING HARDENING PROCESS ALL WORKPIECES OFCOMPLICATED SHAPE OR LONGER THAN 450 mm, MUST BE STRESS RELIEVED.THE STRESS RELIEVING PROCESS HAS TO BE CARRIED OUT AFTER PREMACHININGLIKE MILLING, PLANNING ETC. - WITH SUFFICIENT ALLOWANCE FOR FINISH-MACHINING.

AFTER ANNEALING THE WORKPIECE IS TO BE MACHINED TO THE REQUIREDDIMENSIONS AND THEN BE HARDENED IN DUE FORM.

STRESS RELIEVINGHARDENING AND TEMPERING: SEE W-DX25-40M PAGES 35 - 40

2.6

EUROPE ONLY

31JAN. 2001

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MATERIAL DESIGNATION: 1.2842

STRESS RELIEVING:

PREHEATING:

HARDENING:

PLACE IN THE FURNACE AND HEAT CAREFULLY TO A TEMPERATUREOF 600 - 650 C. SOAK FOR 1 - 3 HOURS.o

ALLOW TO COOL IN THE FURNACE.

HEAD THE WORKPIECE IN SALTBATH OR FURNACE THOROUGHLYAND UNIFORMLY TO 780 - 810 C FOR A MINIMUM OFo

20 MIN./25 mm THICKNESS OF MATERIAL.

WHEN HEATING IN THE FURNACE THE PIECE SHOULD BE PACKEDAND HERMETICALLY SEALED IN A BOX.

CHARCOALPIECES ARE ADDED WHICH ARE NOT ALLOWED TO TOUCH THE PIECE OR IT IS COVERED AT THE SUSCEPTIBLESURFACES WITH CAUTERIZED FINE COKE.

IT IS QUENCHED IN SALTBATH OF 180 - 220 C.o

THE PIECE MUST REST IN THE BATH UNTIL A COMPLETEEQUALIZATION OF TEMPERATURE AND SUBSEQUENTLY QUENCHEDIN AN AIR FLOW.

3

3.1

PLACE IN FURNACE WITH A TEMPERATURE OF 300 - 400 C.o

ALLOW TO SOAK AND THEN TRANSFER TO SALTBATH ORFURNACE WITH A TEMPERATURE OF 650 C.o

WHEN WORKPIECE IS HEATED UNIFORMLY TO THIS TEMPERATUREKEEP AT THIS TEMPERATURE AND SOAK WELL.

EUROPE ONLY

35DEC. 1996

THROUGH HARDENING

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TEMPERING: SHOULD BE CARRIED OUT IMMEDIATELY AFTER HARDENING.PREFERABLY WHEN THE WORKPIECE IS STILL HAND WARM.HEAT SLOWLY AND UNIFORMLY BETWEEN 180 - 220 C INo

SALTBATH.TEMPERATURE TO BE HELD FOR AT LEAST 1 HOUR/25 mm THICKNESS OF MATERIAL.COOL IN ROOM TEMPERATURE.REQUIRED HARDNESS ARE SHOWN ON MFG. STD. W-DX25-40MPAGE 9.TEMPERATURE AND HARDNESS CAN BE SEEN FROM THE DIAGRAMBELOW.

NOT SUITABLE FOR NITRIDING.

0 100 200 300 400 500 600 700 80030

34

38

42

46

50

54

58

62

66

70

TEMPERING TEMPERATURE Co

HARDNESS

HRC

NITRIDING:

EUROPE ONLY

DEC. 199636


THROUGH HARDENING

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STRESS RELIEVING: PLACE IN THE FURNACE AND HEAT CAREFULLY TO A TEMPERA-TURE OF 600 - 650 C. SOAK FOR 1-3 HOURS. o

ALLOW TO COOL IN THE FURNACE.

3.2

PREHEATING: PLACE IN FURNACE WITH A TEMPERATURE OF 300 - 400 C.o

ALLOW TO SOAK AND THEN TRANSFER TO SALTBATH OR FURNACEWITH A TEMPERATURE OF 850 C.o

WHEN THE WORKPIECE IS HEATED UNIFORMLY TO THIS TEMPERA-TURE KEEP AT THIS TEMPERATURE AND SOAK WELL.

HARDENING: HEAT THE WORKPIECE IN SALTBATH OR FURNACE THOROUGHLYAND UNIFORMLY TO 1010-1100 C FOR A MINIMUN OFo

20MIN./25mm THICKNESS OF MATERIAL.GEOMETRICAL SIMPLE PIECES ARE QUENCHED IN THE AIR.GEOMETRICAL COMPLICATED PIECES ARE QUENCHED IN A WARMBATH OF 280 - 300 C (FREE OF SCALE).o

THE PIECES MUST REST IN THE SALTBATH UNTIL A COMPLETEEQUALIZATION OF TEMPERATURE AND SUBSEQUENTLY QUENCHED IN STILL AIR.

WORKPIECES WHICH WILL BE IONITRIDED AFTER HARDENED MUSTBE HEATED IN VACUUM FURNACE OR SALTBATH TO A MAXIMUMAUSTENISATION TEMPERATURE (1100 C).o

THE COOLING MUST TAKE PLACE IN A WARMBATH AT A TEMPERATURE OF 500 C.o

THE PIECES MUST REST IN THE SALTBATH UNTIL A COMPLETEEQUALIZATION OF TEMPERATURE AND SUBSEQUENTLY QUENCHEDIN STILL AIR.

EUROPE ONLY

37JAN. 2001

THROUGH HARDENING

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HRC

HARDNESS

70

66

62

58

54

50

46

42

38

34

30

TEMPERING TEMPERATURE Co

0 100 200 300 400 500 600 700 800

TEMPERING: SHOULD BE CARRIED OUT IMMEDIATELY AFTER HARDENING.PREFERABLY WHEN THE WORKPIECE IS STILL HAND WARM.HEAT SLOWLY AND UNIFORMLY BETWEEN 550-570 C IN SALTBATH.o

TEMPERATURE TO BE HELD FOR AT LEAST 1 HOUR/25mm THICKNESSOF MATERIAL.DOUBLE TEMPER TO SPECIFIED HARDNESS.REQUIRED HARDNESSES ARE SHOWN ON MFG. STD. W-DX25-40M PAGE 9.TEMPERATURE AND HARDNESS CAN BE SEEN FROM THE DIAGRAM BELOW.

IONITRIDING: THE PROCESS IS CARRIED OUT BY THE SUPPLIER.

VERY SUITABLE FOR NITRIDING.NITRIDING:

EUROPE ONLY

DEC. 199638



wdx2501m.pdf

EUROPE ONLYVEHICLE OPERATIONS

CONSTRUCTION SPECIFICATIONSWORLDWIDE DIE DESIGN AND

W-DX

DATE SECTIONPAGE

W-DX25-40M43

DIE MATERIALS


SEGMENTED

WITH HIGH WEAR CONDITION

1.2379 IH

DRAW DIES

BLANK DIES

+ OPTIONAL1.2379 H (ROLLED MAT.)

CVD-COATING.

OR

+ OPTIONAL

SEGMENTS AND INSERTS

CVD-COATING.

1.2382 H ( CAST )

INSERTS

TOOL STEEL MATERIALS

1.2379 IH 1.2382 IH

1.2382 IH

ROLLED MATERIAL CAST MATERIAL

AUGUST 2004



EUROPE ONLY


TRIM DIES

PRODUCTION PANELS < 1,5mm THICK

SEPT. 200144

INSERTS1.2358 IH OR1.2379 IH

CAST BUCK1.2333 IH

PRODUCTION PANELS > 1,5mm THICK

INSERTS1.2358 IH OR1.2379 IH

CAST BUCK1.7140 IH

STEELS1.2320 IH OR1.2358 IH (ROLLED MAT.)

STEELS1.2333 IH OR1.2358 IH (ROLLED MAT.)

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SPEC. TRIM STEELS

SEPT. 2001 45

e.g. INSERT IN LOWER DIE BUCK

SPECIAL WEAK FORMS

FLANGE DIES

1.7140

STRAIGHT FLANGE LINECONTOUR FLANGE LINE

INSERTS1.2382 H + (CVD COATING) OR1.2379 H +(CVD COATING)

INSERTS1.2320 IH OR1.2358 IH(ROLLED MAT.)

INSERTSPMDM 4 OR VANADIS 4

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DRAW AND RESTRIKE DEPRESSIONS

e.g. FLOOR PLAN

SEPT. 2001 47

x x x x x x

xxxxx

x

1.2358 IH

IH

IH


CAST MATERIAL

ROLLED MATERIAL

MAT. NO.

SEL. NO.FORDOLDNO.

HEATTREATMENT

STRENGTHNESSTHROUGHHARDENING

SURFACEHARDENING

1.7140

1.2320

1.2333

1.2382

1.2358

1.2379

PMDM 4

VANADIS 4

G 47CrMn6

G 60CrMoV10-7

SG7

G 59CrMoV18-5

GX155CrVMo12-1

60CrMoV18-5

X155CrVMo12-1

----

----

SOFT ANNEALINGPREHARDENING



SOFT ANNEALING


SOFT ANNEALING

ANNEALING

SOFT ANNEALING

MAX.250 HB800-950N/mm2

MAX.250 HB2800-950N/mm

MAX.250 HB800-950N/mm 2

MAX.285 HB

MAX.250 HB800-950N/mm 2

MAX.255 HB

MAX.280 HB

MAX.235 HB

----

50-60HRC

50-60HRC

55-60HRC

50-60HRC

58-62HRC

59-65HRC

58-63HRC

MAX 56HRC

MAX 62HRC

MAX 62HRC

MAX 62HRC

MAX 62HRC

MAX 62HRC

----

MAX 64HRC

* THE HARDNESS IS TO ADAPT TO RESPECTIVE APPLICATION.

* *

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IONITRIDING

TO ENSURE AN OPTIMAL SURFACE FOR THE DRAW OR FLANGING PROCESS, INSERTS ORFLANGING STEELS MADE FROM 1.2379 WHICH REQUIRE NITRIDING ARE TO BE HEAT-TREATEDIN THE FOLLOWING MANNER.

THE AUSTENISATION TEMPERATURE SHOULD BE BROUGHT TO THE UPPER LIMIT AS WELL ASTHE TEMPERING TEMPERATURE.

THE IONITRIDING PROCESS HAS TO BE CARRIED OUT APPROX. 30 TO 50 C BELOW THEo o

TEMPERING TEMPERATURE AS REDUCED TEMPERATURES LEAD TO AN EXTREME INCREASEIN THE NECESSARY NITRIDING TIME.

AUSTENISATION AND TEMPERING TEMPERATURES TO BE LOOKED FOR IN THE CATALOGUESOF THE APPROPRIATE STEEL VENDORS.

IN ORDER TO INFORM THE COMPANIES CARRYING OUT THE NITRIDING PROCESS, THE TOOLMANUFACTURES RESPECTIVELY THE HARDENING SHOPS ARE TO ESTABLISH A HARDENINGREPORT. THESE REPORTS WILL BE DELIVERED TO THE PLANTS TOGETHER WITH THE DIESAND SHOULD CONTAIN THE FOLLOWING:

1) HARDENING TEMPERATURE

2) TEMPERING TEMPERATURE

3) NUMBER OF TEMPERING PROCESSES

4) HARDENESS IN HRC

INSERTS ON DRAW DIES ARE TO BE IONITRIDED BY THE CORRESPONDING PLANTS AFTERHOME TRYOUT AND AFTER PRODUCTION OF AT LEAST 10.000 PARTS.

4

EUROPE ONLY

DEC. 1996 51


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CVD-COATING5

PREPARATION FOR CVD-COATING (RECOMMENDATION COLOGNE TOOLROOM)

A) ROUGH MACHING 1,5 - 3,0MM.

B) STRESS RELIEVING 3-6 HRS, 600 C - 650 C.o o

C) FINAL MACHINING 0,15 - 0,3MM.

D) HEAT TREATMENT IN A VACUUM FURNACE 1050 C.o

E) TWO TIMES TEMPERING 490 .o

F) FINISHING (GRINDING OR POLISHING) MAX. 5 M.

IT IS RECOMMENDED TO ESTABILISH A HEATING RECORD TO ENABLE ANOPTIMAL TREATMENT OF CVD-COATING.

U

EUROPE ONLY

53DEC. 1996

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WELDING

11. WELDING OF CAST ITEMS

WELDING OF CAST ITEMS STRESSED BY WEAR EG. BOTTOM DIES, BLANKHOLDER AND PUNCHES OF DRAW AND FORM DIES.

BASED ON THE EXPERIENCE AND ON TRIALS CARRIED OUT RECENTLY, ESPECIALLY IN VIEW OF COATED SHEET METAL APPLICATION, WE CONFIRM THE PROCEDURE FOR REPAIR WELDING AND FOR WELDING IN CASE OF ALTERATIONS.

1.AS SHOWN ON THE SKETCHES ON REPAIR AND ALTERATIONS, THE CAST ITEMS HAVE TO BE GROUND OR MILLED TO APPROX. 4 TO 6 mm IN DEPTH.

2.THE INTERMEDIATE LAYER HAS TO BE WELDED WITH THE RELEVANT ROD DEPENDING ON THE CAST MATERIAL (SEE TABLE BELOW) AND TO BE COMPRESSED IMMEDIATELY BY HAMMERING LAYER BY LAYER AS LONG AS THE WELDED MATERIAL IS WARM.

3.THE INTERMEDIATE LAYER HAS TO BE REWORKED EQUAL DISTANTS OF MINUS 2 mm TO THE FINISHED FORM.

4.THE COVERING HAS TO BE WELDED IN 3 LAYERS, WITH THE RELEVANT ROD (SEE TABLE BELOW) AND HAMMERED. CAUTION: A BUILD UP MUCH THICKER THAN 2 mm OR INCONSISTENT THICKNESS MIGHT RESULT IN CRACKS.

5.REWORK TO THE FINISHED FORM.

REPAIR WELDING ALTERATION WELDING

GREEN

ALREADY FLAME HARDENED

EN-JS 1060 (GGG-60)

EN-JL 2060 (EGG-25)

STICK ROD:CASTOLIN 2230

------ALTERNATIVE------

MIG WIRE: ENDOTEC DO23

STICK ROD:CASTOLIN 2230 ------ALTERNATIVE------

MIG WIRE: ENDOTEC DO23

CASTOLIN 27

CASTOLIN 35200 (AFTER FH APPR.30HRc)-----------ALTERNATIVE-------------

CASTOLIN 45352 (AFTER FH APPR.46HRc)

CASTOLIN 27 (WELDING APPR. 43HRc)

-----------ALTERNATIVE------------- CASTOLIN 2R (WELDING APPR. 57HRc)

COVERING LAYERINTERMEDIATE LAYERCAST MATERIAL

2 mm

2 mm

4-6 mm

COVERING LAYER

INTERMEDIATE LAYER

COVERING LAYER

INTERMEDIATE LAYER

EUROPE ONLY

81 JAN. 2001

EN-JS 1060 (GGG-60)

EN-JS 2070 (GGG-70L) SEE PAGES 82-85

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EUROPE ONLY

WELD OF EN-JS2070(GGG-70L)INSIDE THE TOOL SHOP

DRAW DIE OUTER AND INNER PANEL

GENERALLY: RESPECT TECHNIQUE FOR WELDING CAST IRON AS REMOVING THE CAST SKIN, SLIGHT PREHEATING (200-250 C) BEFORE AND HAMMERING AFTER THE WELDING PROCESS.o

BUILDING - UP - WELDING.

1. NEW DIES: CLEAN SURFACE AND NOT BEING IMPREGNATED WITH OIL.

1.1 PUNCH, MATRIX.

FEB. 2000

1.1.1 AREA WHICH IS NOT TO BE HARDENED.

1.1.1.1 REPAIR AREA < 100mm AND 5 TO 10mm DEEP.

IN CASE OF CONNECTION PROBLEMS GO FOR A BUFFER LAYER.

1.1.1.2 REPAIR AREA > 100mm AND DEEPER THEN 10mm.

BUILDING - UP - WELDING.

1 a

DETAIL a

a1

EXPLANATION OF 1 AND 2 SEE LIST ON PAGE 85.

WITH BINDER PROBLEMS USEINTER LAYER CASTOLIN 27.GRIND INTER LAYER 2 TOBECOME A CLEAN AND FLATSURFACE.

2

1

82

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FEB. 2000

1.1.2 AREA WITH SURFACE HARDENING.

INDUCTION OR FLAME HARDENING.

1.1.2.1 BEFORE HARDENING.

1.1.2.1.1 SMALL REPAIR AREAS.

1 INTER LAYER IF MORE THEN 2 LAYERS NECESSARY.

3 PREFERRED

2 ALTERNATIVE

MIN. 2 LAYERS

1.1.2.1.2 BIG REPAIR AREAS.

1H OR FH WITH 54 - 58 HRC. USE FH ONLY EXCEPTION DUE TO BIG TOLERANCE OF THEHARDNESS.

EXPLANATION OF 1 , 2 , AND 3 , SEE LIST ON PAGE 85.

1

3 PREFERRED

2 ALTERNATIVE

MIN. 2 LAYERS

83

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FEB. 2000


1.1.2.2. AFTER HARDENING.

1.1.2.2.1 ONLY SMALL REPAIR AREAS.

2 OR 4 OR 5 MIN. 2 LAYERS.

1 INTER LAYER IF MORE THAN 2 LAYERS NECESSARY.

HOT SPHERE AREA AS SMALL AS POSSIBLE. FRINGE AREA WELD WITH LOW EXTENDING ENERGY. WELD FROM OUTWARD TO INSIDE, CROSSWISE WHEN MANY LAYERS.

LOW VARIATION OF HARDNESS IS NOT AVOIDABLE.RENEWED IH OR FH IS POSSIBLE.

1.1.2.2.2 BIG REPAIR AREAS.

TEMPER THE WHOLE PUNCH OR LOCAL AREAS.WELDING SEE 1.1.2.1.RECHARGE THE PUNCH AND THE NEW KELLERING OF THE PUNCH REQUIRED+ NEW IH OR FH.

1.2 BLANKHOLDERS.

TO BE TREATED AS THE PUNCH. (SEE 1.1.2).

1.3 SPECIAL CASE DRAW RADIUS.

DRAW RADIUS OR RADII WITH HIGH RELATIVE MOVEMENT OF THESHEET METALS.

ATTENTION: NOT ABLE FOR CHROME-PLATING. DON’T WELD MORE THEN 2 LAYERS. GOOD SLIDE QUALITY, NO COLD WELDING ON SURFACE. APPLY ONLY BY RADII WITH EXCESSIVE WEAR.

6

EXPLANATION OF 1 , 2 , 3 , 4 , 5 , AND 6 SEE LIST ON PAGE 85.

84

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FEB. 2000

2. PRODUCTION DIES BEING IMPREGNATED WITH OIL.

PROCEDURE: A) CLEAN DIES, TEMPER SURFACE WITH TORCH. REMOVE DAMAGED MATERIAL. B) WELD CASTOLIN 27 WITH HIGH VOLTAGE. GRIND POROUS WELDING MATERIAL. REPEAT THE PROCEDURE UNTIL NO PORE TREADED. C) HAMMER THE DIES AND PROCEED AS DESCRIBED IN N0.1.

1. DIN8573 ENIFE-1-BG 13 AWSA5.15 ENIFE-CI ELECTRODE CASTOLIN 2-23.

DIN8573 ENIFE-1-BG 23 AWSA5.15 ENIFE-CI ELECTRODE CASTOLIN XHD 2230.

DIN8573 -MSGNIFE-2 AWS FLUX CORED ENDOTEC DO23 CA.210 HB WITH,

WIRE. EMBEDDED BALL-GRAPHITE.

2. DIN8573 ENIFI-1-BG 23 AWSA5.15 EST WIRE CASTOLIN 27 GROUND HARDNESS,

54HRC.AFTER IH OR FH58 HRC.

3. DIN8555 MSG6-60.GTZ AWS WIRE CASTOMAG 45352 MIDDLE ALLOYED,

STEEL GROUND HARDNESS 40 HRC,

AFTER 1H OR FH 60 HRC.

4. DIN8555 E3-UM-60-S AWS ELECTRODE CASTOLIN 2R HIGH ALLOY STEEL,

GROUND HARDNESS 57 HRC,


5. DIN8555 MF3-55-GPST AWS FLUX CORED ENDOTEC DO15 HIGH ALLOY STEEL,

WIRE. GROUND HARDNESS 57 HRC,


6. DIN8555 E20-UM-300-CKPT AWS ELECTRODE CASTOLIN TOOL TEC 54425

PLASMA NITRIDE

PLASMA NITRIDING - IN CASE OF BIG DIFFERENCES IN HARDNESS A HOMOGENEOUS SURFACE CAN BE MANAGED.

CHROME PLATING

CHROME PLATING - BEFORE CHROME PLATING THE PUNCH MUST BE PERFECTLY HARDENED.

3. CONTACTS.

GREAT BRITAIN:CASTOLIN EUTETEC CO.LTD.,DON WIGGINS-ZONE MANAGER.TEL: 07970 243 123.SIMON CLARIDGE-SALES MANAGER.TEL: 07970 234 117.

GERMANY:CASTOLIN GMBH,GUTENBERGSTRASSE 10,D-65830 KRIFTEL.TEL: 06192 / 403-0.FAX: 06192 / 403314.

85 END

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