Conformal Cooling Die Inserts for Area-Specific Hot Stamping
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Solution Overview
Problem
Existing hot stamping processes face limitations in controlling cooling rates and heat transfer surface area due to gun drilled cooling channels, which restricts microstructure variations in stamped articles.
Innovation Solution
A mold assembly with a removable channel insert having a curved shape and projections, integrated with a 3D printed sand mold, allowing for conformal channels with tailored fluid flow regions to achieve precise cooling rates and heat transfer areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If gun drilled cooling channels are used, then the die can be cooled, but the ability to control cooling rates in various areas of the die is reduced
Solution Approach 1:
The patent applies local quality by creating conformal cooling channels that follow the contour of the die cavity, allowing different regions of the die to have customized cooling characteristics. The channels are positioned at varying distances from the cavity surface, enabling area-specific cooling rate control to achieve desired microstructure variations in different parts of the stamped article.
Solution Approach 2:
The patent utilizes curvature by designing cooling channels that conform to the curved surfaces of the die cavity. This conformal geometry allows the cooling channels to closely follow the die contour, maximizing heat transfer surface area and enabling precise control of cooling rates across complex die geometries.
2Temperature
If gun drilled cooling channels are used, then the die can be cooled, but the heat transfer surface area available for cooling is limited
Solution Approach 1:
The conformal cooling channels are designed to closely follow the curved contour of the die cavity, maximizing the heat transfer surface area between the cooling channels and the die. This curvature-based design allows the channels to be positioned optimally throughout the die geometry, significantly increasing the effective cooling surface area compared to traditional straight drilled channels.
3Manufacturing precision
If conformal channels with tailored fluid flow regions are implemented, then microstructure control is improved, but the device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the die into multiple cooling zones with independently controllable channels. Each zone can have tailored fluid flow characteristics, allowing precise control of cooling rates for different microstructure requirements. This modular approach to cooling channel design enables complex microstructure control while managing overall system complexity through systematic zonation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables improved microstructure control and strength in hot stamped articles by allowing for specific cooling rates and heat transfer configurations without compromising die integrity, enhancing design flexibility and efficiency.
Implementation Method 1
The cooled dies may cool the article as it is being stamped. If the cooling rate of the dies is sufficiently high, the microstructure of the stamped article may be converted to a high strength phase.
Implementation Method 2
The plurality of projections integrate the insert with the body and are configured to form inlets and outlets for fluid in the hot stamping die
Data Source
AI summary
A mold assembly for a hot stamping die is provided. The mold assembly includes a mold having a body defining a cavity and a removable channel insert. The removable channel insert is positioned in the cavity and has a curved shape. The removable channel insert also includes a plurality of projections integrating the insert with the body. The removable channel insert is configured to form inlets and outlets for fluid in the hot stamping die upon removal of the insert.