The blanking and forming of materials in cold condition is done in many different application such as; shearing, punching,

cold forging, drawing, cold extrusion, rolling and powder pressing. All applications include high mechanical forces and sliding contact between the tool surface and the work material. There are high demands on tool hardness to give wear resistance and resistance to plastic deformation. In order to improve the wear resistance further some of the cold work steel grades are highly alloyed giving hard particles (carbides) in the matrix. The combination of high hardness and hard carbides is however also impairing the machinability. ASSAB can provide you with tool steels from a program of high quality tool steels covering all your demands. Low alloyed carbon tool steel grades, high-alloyed conventional metallurgy grades as well as powder metallurgical grades together with proper advice regarding tool steel selection and treatments.Depending on the application, the work material and the production series, a cold work tool steel program will contain grades with different combinations of:

Wear resistance Resistance to plastic deformation Chipping resistance Total cracking resistance Good machinability and grind ability
CHEMCIAL COMPOSITION (%) Hardness Ref. STANDARD CHARACTER-ISTICS APPLICATIONS C Mn Cr Mo V W Others supplied approx. AISI W.nr JIS HB 0.95 0.5 0.1 0.1 0.5 190 01 1.251 SKS3 General purpose tool steel, good surface hardness, Cutting: blanking, punching, piercing, cropping, shearing, trimming, wear resistance, easy to harden. clipping. Forming: punching, raising, drawing, rim rolling, spinning, flow forming.

GRADE

DF-2 (DF-3)

ASSAB 88 XW-5 XW-10 XW-41

0,9 0,5 7,8 2,5 0,5

Si 0,9

235

Patented

Mixed-abrasive profile and good resistance to chipping. Good machining and WEDM properties.

2.05 0.8 12.5 1.0 0.6 5.3 1.1 0.2 1.55 0.3 12.0 0.8

1.1

240 215 210

D3/D6 1.2436 SKD2 High performance tool steel. Excellent abrasive wear resistance. A2 D2 1.2363 SKD12 Good hardenability and wear resistance. Excellent size stability. For medium runs. 1.2379 SKD11 High performance tool steel. High wear resistance and toughness.

Blanking and fine blanking, shearing, forming, coining, cold forging, cold extrusion, thread rolling, drawing and deep drawing, powder pressing. Blanking, punching, cropping, shearing, trimming, clipping. Blanking, punching, piercing, cropping, shearing, trimming, clipping. Blanking, fine-blanking, punching, cropping, shearing, trimming, clipping.

(XW-42)

toughness. VANADIS 4 EXTRA 1.4 0.4 4.7 3.5 3.7 Si 0.4 230 Patented Powder tool steel for long run tooling, where high demands on adhesive wear and chipping resistance, is required Powder tool steel. Supreme wear resistance. Prehardened tool steel with good weldability and flame-hardenability

pressing, deep drawing, knives. Blanking, fine blanking and forming of thicker work material such as austenitic stainless steel, mild carbon steels, UHSS, copper and aluminum Blanking and forming,fine-blanking, blanking for electrical sheet, deep drawing, cold forging, slitting knives, powder pressing.

VANADIS 10 2.9 0.5 8.0 1.5 9.8 CARMO

0.6 0.8 4.5 0.5 0.2

300 240-270

Patented Patented

Used in flame-hardened or in the through- hardened condition for blanking and forming of both car body parts (thin sheet) or structural parts (thicker sheet). Hot work temperatures and form different inwear e.g. aluminum, steel or other metals. 1.28 operate 4.2 5.0at 3.1elevated 6.4 260 M3:1 Powderproducts HSS Excellent resistance and Blanking of medium to high carbon steels, blanking of harder ASP 23 tools toughness materials, plastic mould tooling, plastic processing parts

The most common application areas in hot work are die casting, extrusion and forging. The high working temperatures put very high demands on the tool steel. The 1.28 4.2 5.0 3.1 6.4 Co 8.5 300 Powder HSS for cutting tools. Excellent wear Suitable for chipforming multi-edge cutting tools and single-edge ASP 30 properties' profile of material used for hot work should enclude an excellent hot strength asGood wellhot ashardness. a very good ductility resistance and toughness. cutting tools.and Cold toughness. work applicants where exacting demands are Other important tool steel properties are a high resistance against thermal cyclic stresses and a good hot wear resistance. The properties profile should be even in all directions in the tool steel for best performance.

Good strength at high temperatures High ductility and toughness

CHEMCIAL COMPOSITION (%) C Mn Cr Mo V Si Others Hardness Ref. STANDARD CHARACTER-ISTICS supplied AISI W.nr JIS approx. HB 180 H13 1.2344 SKD61 Good resistance to thermal fatigue. The steel is produced by a special melting and refining technique in order to give mechanical properties with maximum isotropy and is certified to meet a minimum average Charpy V-notch test result of 11 J. 160 185 Patented APPLICATIONS

GRADE

0.39 0.4 5.3 1.4 0.9 1.0 S-Max 8407 0.003 SUPREME

Suitable for a wide variety of hot work applications, including tools for high pressure die casting, hot extrusion and press forging, 8407 SUPREME also meets or exceeds NADCA 207-97 specifications.

Dievar 8407 2M

Cr-Mo-V alloyed hot work tool steel 0.39 0.4 5.3 1.4 0.9 1.0

High performance hot work tool steel with very good resistance to heat Excellent choice for die casting, forging and extrusion checking, gross cracking, hot wear and plastic deformation. Tools for extrusion, hot pressing, moulds for plastics.

QRO 90 0.38 0.75 2.6 2.25 0.9 0.3 SUPREME HOTVAR

180

H13 1.2344 SKD61 Hot work tool steel with overall good ductility, toughness, wear resistance, hardenability and machinability. 8407 2M is specially processed to provide the best overall product consistency and uniformity available in a conventionally produced AISI H13 or JIS SKD61 type of tool steel Patented Very good high temperature strength and very good thermal fatigue resistance.

Die casting dies and associated tooling, extrusion dies and extrusion tooling, forging dies.

Choosing the optimum mould material for best tooling and production economy. When a new moulded part is to be produced many important decisions have to be made in order to fulfil all requirements set. Decisions will depend on plastic material, production method, multi or single cavity number of parts to be produced, tolerance and surface finish.

Eventually a decision will be made about suitable mould material to be use. ASSAB can help ensure that the final moulding result will be reached by recommending optimum the best mould material for the specific application. In our product program you will find a material suitable for your needs. Right choice of tool materials for plastic moulding tools, should achieve:

High surfaces finish Corrosion resistance Wear resistance High thermal conductivity Good surface finish after EDM or photoetching
CHEMCIAL COMPOSITION (%) C Mn Cr Mo V W Others 0.37 1.4 2.0 0.2 Ni 1.0 Hardness Ref. STANDARD CHARACTER-ISTICS supplied approx. AISI W.nr JIS HB 340- 380 P-20 1.2738 Modified prehardened plastic mould steel. Very mod good polishabilty. APPLICATIONS

GRADE

718HH

S<0.01

Injection moulds for themo-plastics, extrusion dies for thermoplastics, blow moulds, forming tools, press- brake dies, structural components, shafts. Injection moulds for themo- plastics, extrusion dies for thermoplastics, blow moulds, forming tools, machine components. Recommended where extreme surface finishes are required, such as lens moulds and CD moulds. Corrosion/staining resistance, wear resistance, high surface finish. For all type of moulds, especially suited for larger tools where corrosion in production is unacceptable and where high surface finish is required. Electronics industry: connectors, plugs, switches, resistors, integrated circuits. Food processing industry: corrosion resistance and wear resistance. Holders/bolsters for plastic moulds, plastic and rubber moulds with low requirements on polishability, dies for plastic extrusion and constructional parts. Blow moulding, vacuum forming, foam moulding, rubber moulds, footwear moulds, injection moulds, RIM-forming, jigs and fixtures, bolsters and holders. Typical blanking die where it could be used because of the high demands on otughness. Mould for the production of electrical components.

618 Polmax

0.38 1.4 2.0 0.2 0,38 0,5 13,6 0,3 0.3

Ni 1.0 Si 0,9

290- 330 200 200 250

P-20 mod

1.2738

Prehardened plastic mould steel. Good polishability and good machinability Excellent polishability. Good resistance to corrosion and wear. Good machinability.

STAVAX ESR 0.38 0.5 13.6 STAVAX Supreme ELMAX RAMAX 2 PRODAX CALMAX

420 mod AISI 420 mod

1.2083

Stainless plastic mould steel with excellent polishability and corrosion resistance. Stainless mould steel with a unique combination of toughness, corrosion resistance and throughhardening properties. Powder tool steel. Stainless plastic mould steel with high wear resistance.

Cr-Ni-Mo-V alloyed

1.7 0.3 18.0 1.0 3.0

240

0.28 1.1 16.7

S 0.12

300- 340

Stainless steel for holder blocks with excellent machinability and corrosion resistance. Aluminum for plastic moulds, blow moulding and vacuum moulding Patented High toughness, good wear resistance and good polishability steel for plastic moulds.

Tooling Aluminium

145

0.6 0.8 4.5 0.5 0.2

200

CORRAX MOLDMAX LH/MM

MOLDMAX XL

0.03 0.3 12.0 1.4

Ni 9.2 Mo 1.4 AI 1.6

32 HRC

Patented

Age hardening stainless steel with superior corrosion resistance.

Tooling Beryllium Copper

LH 30 HRC MM 40 HRC

Injection moulds for corrosive plastics, rubber, medical and food industry; Extrusion dies; Plastic processing (screws, nozzles); Engineering parts. Beryllium copper for plastic moulds. Excellent heat Blow moulds: pinch offs, neck rings and handle inserts. Injection conductivity. moulds: moulds, cores, and inserts.

PROTHERM EM33 EM38

Tooling Beryllium Copper 9Ni 6Sn Balance Cu Tooling Beryllium Copper

28 32 HRC 190

Copper alloy with high thermal conductivity and high strength Beryllium copper for plastic moulds. Extremely high thermal conductivity. Prehardened plastic mould and holder steel with excellent toughness and machinability. Prehardened plastic mould steel with high hardness

Primarily for core inserts in larger injection moulds. Injection moulds, blow moulds, cores and inserts for all plastics, including corrosive grades. Nozzle tips, gates and manifolds for hot runner systems. Plastic and rubber moulds, support plates and constructional parts. Stripper plates in blanking application. Holders/bolsters for plastic moulds and die casting dies. Injection moulds and extrusion dies for thermoplastics. Rubber moulds and blow moulds. Stripper plates in blanking application

Micro alloyed steel

280-340

Micro alloyed steel

350 - 410

We can supply a large variety of standardized machinery steels in flat, round and square sections. The programme includes steels with highly improved machinability for high productivity.
GRADE CHEMCIAL COMPOSITION Hardness supplied Ref. STANDARD CHARACTER-ISTICS (%) approx. HR C Mn Cr Mo V AISI W.nr JIS 0.35 0.70 1.40 1.40 0.20 275- 335 4340 1.6582 SNCMB High strength machinery steel.Suitable for induction and flamehardening 0.42 0.75 1.05 0.20 245- 290 Max. 217 210 215- 260 4140 3115 APPLICATIONS

705 709 7210 760 707

Suitable for induction hardening and can be nitrided or tuffrided to a surface hardness of 600-650 Vickers.

1.7225 SCM4 Alloyed machinery steel suitable for induction Suitable for flame and induction hardening and can be nitrided or tuffrided to and flamehardening a surface hardness of 600 - 650 Vickers. SNC21 Alloyed case hardening steel. For applications requiring a hard, wear resistant surface and a tough core, such as transmissions components for the automotive industry. Punch holders (jigs), die holders (fixtures) guide plates (simple bending dies), backing plates (simple structural components). Used for shafts, gears, sprockets, etc., particularly when weldability is required.

0.15 0.90 0.80 1.20 0.10 0.45 0.70 0.25 0.75 1.05 0.20

1045/ 1.1730 S50C General utility machinery steel for parts 1050 requiring wear resistance at low loads. 4130 1.7218 SCM2 Alloyed machinery steel suitable for welding

Martempering

|A|B|C|D|E|F|G|H|I|J|K|L|M|N|O|P|Q|R|S|T|U|V|W|X|Y|Z|

Definition: A heat treatment involving austenitisation followed by step quenching, at a rate fast enough to avoid the formation of ferrite, pearlite or bainite to a temperature slightly above the Ms point. Soaking must be long enough to avoid the formation of bainite. The advantage of martempering is the reduction of thermal stresses compared to normal quenching. This prevents cracking and minimises distortion.

PRESS CAPACITY CALCULATIONS

Go to spreadsheet

BLANKING

Where F(b) = Blanking force (kN), P = Perimeter of blank (mm), S(s) = Shear strength (MPa), c = a constant for impact loadings. Grinding a shear angle on a punch minimises the shock load on a press and gives a quieter punch operation. For zero shear, when s = 0, c = 1.25. For part shear, when s = 0.3t, c = 1.0. For full shear, when s = t, c = 0.75. (NB: on a small diameter, multi-punch set-up, staggering the length of punches gives a similar effect on shock loads.) e.g. 150mm diameter blank in 3mm mild steel with part shear on punch gives:

DRAWING

Where F(d) = Drawing force (kN), P = Perimeter of draw (mm), S(y) = Yield strength (MPa), b = a constant for nondraw areas, d = a factor to be used when using a die cushion. When drawing circles, b = 1.0. When drawing irregular forms, corners are non-draw areas and b should be reduced by 0.1 for each corner where the radius is less than 0.3 times the length of the shortest adjacent side. e.g. 150 x 50 pan with 10mm radius corners in 1.6mm mild steel.

Blanking Force
Enter data Either Or Or Quantity of blanks or holes Diameter of blank or hole Width of blank or hole Length of blank or hole Perimeter of blank (if known) Thickness of material Shear strength of material Shear factor for punch or die (place a 1 in only one box) mm mm mm mm mm Mpa full shear part shear no shear

320 1

Force required for blanking 0

tons

Drawing Force
Perimeter of draw Thickness of material Yield strength of material No of "corners" * Die cushion (1 for yes) Enter data mm mm 310 Mpa

Force required for drawing

tons

* only count a "corner" if its radius is < 0.3 x length of shortest adjacent side
PIN AND BUSH CALCULATIONS

NB: The following calculations allow for 0.25 inches die re-grind allowance. If a greater allowance is required, reduce pin and bush lengths accordingly.

MAX PIN LENGTH = Shut height -- 0.5 inches MAX BUSH LENGTH = Shut height -- Bottom plate thickness -- 0.75 inches MIN BUSH LENGTH = Shut height + Stroke -- Pin length + 0.5 inches NB: Where min bush length is greater than max bush length, the bushes leave the pins. In this instance, the maximum dimension takes preference.

TYPICAL MATERIAL STRENGTHS - MPa

Yield Mild Steel Stainless Hot rolled Cold rolled Annealed Half hard Full hard 310 260 280 750 950

Shear 320 290 620 850 1050 Aluminium Copper Zinc Brass Soft Hard

Yield 120 70 --100 350

Shear 140 180 120 220 290