Swedish tool steel in every language - ascamm.org · Swedish tool steel in every language Short...
Transcript of Swedish tool steel in every language - ascamm.org · Swedish tool steel in every language Short...
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Swedish tool steel in every language
Short lead times, consistent supply and service support worldwide. For Uddeholm, business has no borders. Our presence on every continent guarantees that you always get the same high quality of tool steel wherever you are.
Material Selection 1
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Mould steel selection
LENA RÅHLÉN, PRODUCT MANAGER PLASTIC MOULD MATERIALS, UDDEHOLMS AB
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Factors influencing a plastic mould performance
Polymer Polymer Mould Manufacturing
Part Design
Mould Design
Polymer
Use and Maintenance
Heat treatment
Steel grade and hardness selection
Material Selection 3
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• Moulding method
• Plastic material
• Mould size
• Number of shots
• Surface finish
Important parameters for mould steel selection:
Material Selection 4
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Plastic Processing Methods
Process
• Plastic extrusion
• Compression moulding
• Blow moulding
• Injection moulding
Critical property
• Wear and corrosion resistance
• High strength and wear resistance
• Corrosion resistance
• Wear and corrosion resistance, strength and
ductility
•
Material Selection 5
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Important to know about the plastic raw material for the right mould material recommendation
It is not possible to recommend one steel grade just by knowing the name of the plastic material.
What do we need to know about the plastic used?
To find out Possible problem
Temperature High Tempering effect
Injection pressure High Indentations/wear, flash on plastic, cracking
Reinforcement Glas fibre Abrasive wear
Other additives Flame retardent additives, eg halogens
Corrosion
Material Selection 6
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Increasing wear resistance
ALUMEC 89 Soft annealed steel
~45-58 HRC
~30-45 HRC
PM steels
UNIMAX STAVAX ESR MIRRAX ESR ORVAR SUPREME
MIRRAX 40 NIMAX CORRAX IMPAX SUPREME MOLDMAX HH/XL RAMAX HH HOLDAX ROYALLOY
>58 HRC
~150-250 HB
Steel grades and hardness recommended depending on needed wear resistance
Need for higher abrasive wear resistance when using fiber reinforced plastic
Material Selection 7
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Same hardness, but different abrasive wear resistance
SVERKER 3 Conventional 58-60 HRC
VANADIS 4 PM
58-60 HRC
Carbides
UNIMAX Conventional/ESR
~58 HRC
Material Selection 8
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• The bigger the mould, the higher the demand on toughness
o High clamping force in big injection moulding machines
• The bigger the mould, the more difficult to heat treat
o What heat treatment facility is locally available?
Mould size
Material Selection 9
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Grades recommended for big moulds for plastic applications
Uddeholm grade Standard Working hardness
Prehardened IMPAX SUPREME NIMAX MIRRAX 40 High Hardness ORVAR SUPREME VIDAR 1 ESR MIRRAX ESR
W Nr: 1.2738, AISI P20 W Nr 1.2344, AISI H13 W Nr 1.2343, AISI H11 ~ AISI 420 Modified
290-330 HB 360-400 HB 360-400 HB 46-48 HRC 46-48 HRC 46-48 HRC
Material Selection 10
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Long runs > 1.000.000 shot
High hardness steels 40-65 HRC
Medium runs 100.000-1.000.000 shots
Prehardened steel 30-45 HRC
Short runs <100.000 shots
Soft annealed steel or aluminium 160-250 HB
What is a long or a short run?
Long or short run is relative. Short run for a simple part can be long run for a highly reinforced engineering plastic part
Material Selection 11
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ALUMEC 89 Soft annealed steel
~45-58 HRC
~30-45 HRC
PM steels
UNIMAX STAVAX ESR MIRRAX ESR ORVAR SUPREME
MIRRAX 40 NIMAX CORRAX IMPAX SUPREME MOLDMAX HH/XL RAMAX HH HOLDAX ROYALLOY
Increasing wear resistance
>58 HRC
~150-250 HB
Steel grades recommended for different expected number of shots
Material Selection 12
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Surface demands
o polished
o etched
o EDM´d
Important material properties
o low inclusion content
o homogeneity
Surface finish
Material Selection 13
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Recommended:
Electro Slagg Remelted
o POLMAX
o STAVAX ESR
o MIRRAX ESR
o ORVAR SUPREME
o VIDAR 1 ESR
o UNIMAX
o MIRRAX 40
Powder Metallurgy
o ELMAX
o VANADIS
Conventional Steel
o IMPAX SUPREME
o NIMAX
Not recommended:
Holder material with high sulphur content
o RAMAX HH
o ROYALLOY
Conventionally produced high carbon high alloyed steels:
o SVERKER-type (D2 type)
Surface finish- Steels for high requirements
Material Selection 14
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Factors that affect the surface finish
Material Selection
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Minimize the risk of corrosion
Mould design
- Good surface finish
- Avoid contact between different metals
Steel
- Corrosion resistant steel, high Cr-content
- Surface coating
Production
- Cooling water, avoid Cl
Material Selection 16
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Material Selection 17
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The ”Stainless Concept” from Uddeholms AB, consists of eight stainless steel grades
Stainless concept
Mould base material Mould material
Material Selection
ELMAX
POLMAX STAVAX ESR
CORRAX
MIRRAX 40 ROYALLOY
RAMAX HH MIRRAX ESR
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Maintenance
Visible costs Mould material Mouldmaking costs
Hidden costs Cleaning Repolishing Repair welding Stop in production Delays in deliveries
Material Selection 19
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Summary Critical properties for mould material
•Long run moulds
•Reinforced plastic Wear resistance and
hardness
•”Crack resistance” Toughness
• Plastic raw material
• Cooling water
• Maintenance Corrosion resistance
• Surface finish
• Ductility
• Fatigue resistance Cleanliness
•Cycle time
•Tolerances Thermal conductivity
Material Selection 20
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Industry trends and demands Plastics
• Longer tool life:
- At least 1 million
- More than 2 M
• Improved part quality
- High surface finish
- Less deformation
- Less flashes
• Increased productivity
- More productive tools
- Less down time
- Less maintenance
Material Selection 21
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Grades used for plastic moulds -prehardened steel grades
Uddeholm grade Standard Delivery condition (HB)
IMPAX SUPREME NIMAX MIRRAX 40 HOLDAX RAMAX HH ROYALLOY
(W Nr1.2738), AISI P20 W.nr: 1.2312
290-330 360-400 360-400 290-330 320-350 290-330
Material Selection 22
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Material Selection
Uddeholm Mirrax 40 a versatile corrosion resistant mould steel for convenient making of demanding moulds
Fast tool making
- No heat treatment necessary
- Easy to machine
Excellent surface finish possible
- ESR remelted
Less maintenance
- Corrosion resistance
- High prehard hardness
Safer production
- Toughness/ductility
Advantages for tool maker and/or tool user:
Uddeholm Mirrax 40 for many different types of moulds and products
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Material Selection
Uddeholm Mirrax 40 Applications
Main applications includes:
• Moulds for corrosive and/or recycled plastics, both for extrusion and
injection moulding
• Moulds with complicated design causing problem with cracking or
distorsion/dimensional changes during heat treatment
• Moulds with demands on polishability/etchability
• Moulds with demands on corrosion resistance for low maintenance
Examples:
• Moulds for flat screen TV´s and panels
• Head & Tail Lamps
• General moulds, esp. for corrosive resins
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Material Selection 25
Uddeholm RoyAlloy
Applications
Mould bases
Plastic and rubber moulds with low demands on surface finish
Constructional parts
Plastic extrusion
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Material Selection 26
Uddeholm RoyAlloy Features:
Enhanced Machinability
Improved Stability
Elimination of Brittle Failures
Greater Ductility
Consistent Hardness
Superior Weldability
Better Plate Surface and Appearance
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Material Selection 27
Uddeholm RoyAlloy Enhanced machinability
Enhanced surface finishes and threads
Increased cutting tool life
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Material Selection 28
RoyAlloy plate 152mm x 711mm x 813mm (6”x 28”x32”) After extensive machining, distortion corner to corner - 0.15mm (0.006”)
Uddeholm RoyAlloy Enhanced machinability
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Uddeholm Nimax
Material Selection
A low carbon mould steel delivered at a hardness of ~40 HRC.
A challenge to the traditional
W Nr 1.2738/P20 High Hard grades
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Material Selection
EDM surface properties rough EDM Cu electrode
Distance from surface (mm)
200
300
400
500
600
700
800
0 0,02 0,04 0,06 0,08 0,1 0,12
Ha
rdn
ess (
mH
V5
0)
1.2714 1.2738 Nimax-2
No hard layer after EDM and no need for tempering
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Material
Absorbed Energy, (J)
HB S-T T-L L-T
C 1 ~ 395 5.8 11.0 16.1
N 80 ~ 402 5.1 5.8 12.5
Nimax ~ 373 33.1 34 41.2
2738 HH ~ 420 5.5 10.2 12.9
T 44 ~ 425 9 14 14
L-T = longitudinal (length) direction T-L = transverse (width) direction S-T = short transverse (thickness) direction = weakest direction
Toughness, Charpy-V
Material Selection
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Uddeholm Nimax
Advantages for tool maker • Short machining time and low tool wear
- Good machinability
• Short time needed to achieve fine surface finish
- Finer surfaces after machining
• Short grinding time after EDM
- No hard ”white layer” after EDM’ing and no need for tempering
• Good polishability - Low amount of inclusions and good
structure
• Easy to weld
- No preheating or post treatment necessary
Advantages for tool user • Safe mould use
- Good toughness
• Good wear and indentation resistance
- Supplied at ~40 HRC
• Good wear resistance after nitriding - High surface hardness after nitriding
• Consistent properties through large
sections - More uniform hardness over the cross
section
• Easy to weld
- No preheating or post treatment necessary
Material Selection 32
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Applications
• Moulds for plastic injection
- Appliances
- Panels and handles
- Packaging industry
- Containers of different types
- Automotive industry
- Larger interior parts
- Reflectors
• Holders for forging and die casting dies
• Hot runner manifolds
• Engineering parts
Material Selection 33
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Grades used for plastic moulds - high hardness steel grade
Uddeholm grade Standard Working hardness (HRC)
Delivery condition (HB)
ORVAR SUPREME VIDAR 1 ESR STAVAX ESR MIRRAX ESR POLMAX UNIMAX CORRAX ELMAX VANADIS 4 EXTRA
W.nr: 1.2344, AISI H13 W.nr: 1.2343, AISI H11 W.nr: ~1.2083, AISI 420
46-52 46-52 50-52 50-52 50-52 52-58 32-50 56-58 60-64
185 185 190 250 190 200 34 HRC 250 250-290
Material Selection 34
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Grades used for plastic moulds -other alloys
Grade Alloy type Delivery condition (HB)
ALUMEC 89 (Prodax) MOLDMAX HH MOLDMAX XL
Aluminium alloy (7000 series) Beryllium Cupper Cupper alloy
165 360 280
Material Selection 35
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Welding filler material from Uddeholm
Welding filler material
Uddeholm Impax Supreme
Weld/TIG Weld
Uddeholm Nimax
TIG Weld/Laser Weld
Uddeholm Corrax TIG Weld
Uddeholm Mirrax TIG Weld
Uddeholm Stavax ESR
TIG Weld/Laser Weld
Uddeholm Unimax TIG Weld
Moldmax Weldpak
Material Selection 36
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Property guideline
Material Selection 37
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