Modern tool design for component grading incorporating simulation models, efficient tool cooling concepts and tool coating systems

This article describes the studies currently being conducted to optimize the design of tools for the press hardening process, in particular for increasing process reliability in the production of components with graded hardness characteristics. What this means in terms of the demands placed on modern press-hardening tools and their representation by simulative means, both now and in the future, is considerably different from tools for conventional metal forming. In particular, the desire to produce components with locally different mechanical characteristics (‘tailored tempering’) calls for the improved interaction between mechanical and thermal tool characteristics, especially tool materials, coatings, tribological conditions and appropriately coordinated cooling concepts with significant dependence on temperature. In the following a range of different solutions are shown and discussed. Thermo-mechanical and thermo-fluid simulation have a critical role to play in evaluating and reviewing the press hardening tool system as a whole. This article will point out the current possibilities within the coupled thermo-fluid simulation.