Wear measurement methodology and test facility to increase the efficiency of hot stamping for high performance component production (TESTTOOL) : final report

The main objectives of the project have been the development of a measuring methodology and the set-up of a test facility to evaluate the tribo-thermomechanical behaviour of the tool-workpiece system in sheet metal hot stamping. To reach these objectives all relevant aspects concerning hot stamping processes have been taken into account: in WP1 the thermo and tribo-mechanical solicitations acting on the tool-workpiece interface during hot stamping of an industrial reference component have been identified. The heat exchange between tool and work piece has been analysed and tribo-mechanical properties of the sheet coatings have been studied in WP2. The effect of process parameters on thermo-mechanical solicitations affecting tool-workpiece interactions has been studied in WP3. The TestTool facility has been designed and built-up in WP4. Different techniques for analysis of wear generated on hot stamping tools have been evaluated and verified in WP5. Finally, in WP6 the developed TestTool facility has been validated for accurately measuring wear in tools for hot stamping applications and lifetime of hot stamping tools estimation. The achievement of project objectives has enabled the detailed study of wear phenomena affecting hot stamping processes, the evaluation of new combinations of sheet metal, tool steel and coatings and the prediction of tool failure, thus broadening the application range of high complexity and performance hot stamping components.