Segmented Press Mold for Hot Stamping Cold Trim
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Solution Overview
Problem
The high cost and reduced competitiveness in manufacturing press molds for cutting 150 kg-level steel sheets due to the expense of using superhard alloys and the inefficiency of laser-cutting methods, which increase production time and costs while decreasing mold lifespan.
Innovation Solution
A method involving diffusion bonding of different steel bodies, including superhard steel and hot alloy tool steel, followed by precise polishing, heat treatment, and wire processing to create a press mold that can efficiently cut 150 kg-level steel sheets at a lower cost, improving mold lifespan and mass production capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a steel mold is made of superhard alloy to enable cutting of 150 kg-level steel sheet, then the cutting capability is improved, but the manufacturing cost is significantly increased
Solution Approach 1:
The steel mold is divided into two segments: a superhard alloy cutting edge portion for cutting 150 kg-level steel sheets and a body portion made of cost-effective alloy tool steel. This segmentation allows the expensive superhard material to be used only where necessary (at the cutting edge) while the majority of the mold uses cheaper material, thus reducing overall manufacturing cost while maintaining cutting capability.
Solution Approach 2:
The mold applies local quality by using superhard alloy only at the cutting edge portion where high hardness and wear resistance are required for cutting tough steel sheets, while the body portion uses standard alloy tool steel with adequate but not excessive properties. This localized application of high-performance material optimizes the balance between cutting capability and manufacturing cost.
2Ease of manufacture
If a steel mold is made of general cold alloy tool steel to reduce manufacturing cost, then the manufacturing cost is decreased, but the cutting capability on 150 kg-level steel sheet is lost
Solution Approach 1:
The mold is segmented into a body portion made of general cold alloy tool steel (which provides cost effectiveness) and a cutting edge portion made of superhard alloy (which provides the necessary cutting capability). This segmentation allows the use of cheaper materials for the majority of the mold structure while concentrating the expensive high-performance material only where it is functionally required.
Solution Approach 2:
The mold structure implements local quality by assigning different material properties to different regions: the body portion uses standard alloy tool steel with adequate mechanical properties for structural support, while the cutting edge portion uses superhard alloy with exceptional hardness and wear resistance specifically where contact with 150 kg-level steel sheets occurs.
3Ease of manufacture
If laser-cutting method is used to cut product edges to avoid mold cost, then the manufacturing cost is reduced, but the production time is significantly increased
Solution Approach 1:
The invention replaces the laser-cutting process (thermal/optical system) with a mechanical press-molding process using a specially designed steel mold with superhard alloy cutting edges. This substitution enables mass production through rapid mechanical pressing and cutting in a single operation, dramatically reducing production time compared to sequential laser-cutting while maintaining cost effectiveness through the segmented mold structure.
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
The method significantly reduces the development cost of press molds and increases their lifespan, enabling cost-effective mass production of hot stamping cold trims with improved cutting efficiency and competitiveness.
Implementation Method 1
bonding a first steel body corresponding to a superhard steel body and a second steel body corresponding to a hot alloy tool steel body, which are made of different materials, to each other to form a single body mold material
Implementation Method 2
heat-treating the mold material
Data Source
AI summary
A method of manufacturing a press mold for mass-producing a hot stamping cold trim includes bonding first and second steel bodies made of different materials to form a single body mold material, polishing a bottom surface and one edge surface of the mold material with processing margins, processing edge surfaces other than the one edge surface on which a bonding part is positioned, processing reference holes for guide pins and a reference surface, forming bolt holes penetrating through the reference surface and the bottom surface, processing a surface of the first steel body in a predetermined shape, heat-treating the mold material, and polishing the bottom surface and the one edge surface having the processing margins at desired accurate dimensions and wire-processing the one edge surface with the processing margin to configure a front end part having the desired accurate dimension.