Abstract
Additive manufacturing (AM) can be used to manufacture tool inserts with cooling channels conforming to the shape of the part to be produced. This results in shorter cycle times and improved quality. In the hot stamping industry, there is need to reduce cycle time and improve quality. The process differs from injection moulding since it involves larger tool inserts, high temperature and forces. In hot stamping tools, the cooling channels are in the form of straight drilled channels. These channels do not have the capacity to cool complex shaped parts consistently due to restrictions in machining. There is need for further studies on the design of hot stamping tools with AM-based cooling channels. The aim of this paper is to propose a method for designing hot stamping tools with conformal cooling channels. The method involves firstly evaluating the part to decide whether it is suitable for AM application, determining conformal cooling parameters and developing alternative layouts. This is followed by selection of the optimum layout and obtaining the cooling system parameters.
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06973-z/MediaObjects/170_2021_6973_Fig1_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06973-z/MediaObjects/170_2021_6973_Fig2_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06973-z/MediaObjects/170_2021_6973_Fig3_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06973-z/MediaObjects/170_2021_6973_Fig4_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06973-z/MediaObjects/170_2021_6973_Fig5_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06973-z/MediaObjects/170_2021_6973_Fig6_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06973-z/MediaObjects/170_2021_6973_Fig7_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06973-z/MediaObjects/170_2021_6973_Fig8_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06973-z/MediaObjects/170_2021_6973_Fig9_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06973-z/MediaObjects/170_2021_6973_Fig10_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06973-z/MediaObjects/170_2021_6973_Fig11_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06973-z/MediaObjects/170_2021_6973_Fig12_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06973-z/MediaObjects/170_2021_6973_Fig13_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06973-z/MediaObjects/170_2021_6973_Fig14_HTML.png)
Similar content being viewed by others
References
Karbasian H, Tekkaya AE (2010) A review on hot stamping. J Mater Process Technol 210(15):2103–2118
M. F. Li, T. S. Chiang, J. H. Tseng, and C. N. Tsai, “Hot stamping of door impact beam,” Procedia Eng, vol. 81, no. October, pp. 1786–1791, 2014.
Lim WS, Choi HS, Ahn SY, Kim BM (2014) Cooling channel design of hot stamping tools for uniform high-strength components in hot stamping process. Int J Adv Manuf Technol 70(5–8):1189–1203
Lv M, Gu Z, Li X, Xu H (2016) Optimal design for cooling system of hot stamping dies. ISIJ Int:1–9
Steinbeiss H, So H, Michelitsch T, Hoffmann H (2007) Method for optimizing the cooling design of hot stamping tools. Prod Eng 1(2):149–155
Muvunzi R, Hagedorn-Hansen D, Matope S, Madyibi X, Swart CB, Nagel M (2020) Industry case study: process chain for manufacturing of a large hybrid hot stamping tool with conformal cooling channels. Int J Adv Manuf Technol 110(7–8):1723–1730
De Shan Z, Ye YS, Zhang ML, Wang BY (2013) Hot-stamping die-cooling system for vehicle door beams. Int J Precis Eng Manuf 14(7):1251–1255
Zhong-de S, Mi-Ian Z, Chao J, Ying X, Wem-juan R (2010) Basic study on die cooling system of hot stamping process. Int Conf Adv Technol Des Manuf 67(0 2):5–8
Xian XD, Wang YL (2014) The parametric design of cooling system of hot stamping die. Adv Mater Res 1063:276–279
Mazur M, Brincat P, Leary M, Brandt M (2017) Numerical and experimental evaluation of a conformally cooled H13 steel injection mould manufactured with selective laser melting. Int J Adv Manuf Technol 93(1–4):881–900
Dimitrov D, and Moammer A (2010) “Investigating the impact of conformal cooling on the performance of injection moulds for the packaging industry,” 32:226–238
Mueller B, Hund R, Malek R, Gebauer M, Polster S, Kotzian M, Volkswagen AG (2013) Added value in tooling for sheet metal forming through additive manufacturing. In International Conference on Competitive Manufacturing pp 1-7
Stoll P, Spierings A, Gebauer M, Müller B, Polster S, Feld T and Zurbrügg A (2016) High performance sheet metal forming tooling by additive manufacturing. In iCAT 2016: Proceedings of the 6th International Conference on Additive Technologies pp. 354-361
Mueller B, Gebauer M, Polster S, Neugebauer R, Malek R, Kotzian M and Hund R (2013) “Ressource-efficient hot sheet metal forming by innovative die cooling with laser beam melted tooling components”. In High Value Manufacturing: Advanced Research in Virtual and Rapid Prototyping: Proceedings of the 6th International Conference on Advanced Research in Virtual and Rapid Prototyping, Leiria, Portugal, pp. 321. CRC Press.
Kanbur BB, Suping S, Duan F (2020) Design and optimization of conformal cooling channels for injection molding: a review. Int J Adv Manuf Technol 106(7):3253–3271
Cortina M, Arrizubieta JI, Calleja A, Ukar E, and Alberdi A (2018) “Case study to illustrate the potential of conformal cooling channels for hot stamping dies manufactured using hybrid process of laser metal deposition (LMD) and milling,” Metals (Basel), 8:2
Liu HS, Xing ZW, Bao J, Song BY (2010) Investigation of the hot-stamping process for advanced high-strength steel sheet by numerical simulation. J Mater Eng Perform 19(3):325–334
Lim WS, Choi HS, Ahn SY, and Kim BM (2014)“Cooling channel design of hot stamping tools for uniform high-strength components in hot stamping process,” Int J Adv Manuf Technol, vol. 70is the i, no. 5–8, pp. 1189–1203
Yun S, Kwon J, Cho W, Lee D, Kim Y (2020) Performance improvement of hot stamping die for patchwork blank using mixed cooling channel designs with straight and conformal channels. Appl Therm Eng 165:114562
A. Moammer, “Thermal management of moulds and dies: a contribution to improved design and manufacture of tooling for injection moulding, (Doctoral dissertation, University of Stellenbosch). 2011.
Xiaorong and Xu (1999)“Conformal cooling and rapid thermal cycling in injection molding with 3D printed tools,”
Hall M, Krystofik M (2015) Conformal cooling. Doctoral dissertation, Massachusetts Institute of Technology
Xu X, Sachs E, Allen S (2001) The design of conformal cooling channels in injection molding tooling. Polym Eng Sci 41(7):1265–1279
Lv M, Gu Z, Li X, and Xu H (2016) “Optimal design for cooling system of hot stamping dies,” vol. 56, no. 12, pp. 2250–2258
Anderson, David M (2020) Design for manufacturability: how to use concurrent engineering to rapidly develop low-cost, high-quality products for lean production. CRC press
Boivie K, Sørby K, Brøtan V, Ystgaard P (2011) Development of a hybrid manufacturing cell; integration of additive manufacturing with CNC machining background: industrial case studies Case 1: insert for a bracket to an office chair. 22nd Annu Int Solid Free Fabr Symp - An Addit Manuf Conf SFF 2011:153–163
Valiantzas JD (2008) Explicit power formula for the Darcy–Weisbach pipe flow equation: application in optimal pipeline design. J Irrig Drain Eng 134(4):454–461
Becker TH, DImitrov D (2016) The achievable mechanical properties of SLM produced Maraging Steel 300 components. Rapid Prototyp J 22(3):487–494
Schmidt M, Merklein M, Bourell D, Dimitrov D, Hausotte T, Wegener K, Levy GN (2017) Laser based additive manufacturing in industry and academia. CIRP Ann 66(2):561–583
Mugwagwa L, Dimitrov D, Matope S, Yadroitsev I (Jan. 2018) Influence of process parameters on residual stress related distortions in selective laser melting. Procedia Manuf 21:92–99
Zaeh MF, Branner G (2010) Investigations on residual stresses and deformations in selective laser melting. Prod Eng 4(1):35–45
Park HS and Pham NH (2007) “Automatically generating conformal cooling channel design for plastic injection molding,” in Annals of DAAAM and Proceedings of the International DAAAM Symposium, pp. 539–540.
Muvunzi R, Dimitrov DM and S. Matope, “Heat transfer in a hot stamping process: a review,” R D J. South African Inst. Mech. Eng. 2, vol. 33, no. September 2016, pp. 75–84, 2017.
Bahrami M (2011) Forced convection heat transfer mechanism of forced convection. ENSC 388:1–11
Montgomery DC (2012) Design and Analysis of Experiments, Eight edn
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Muvunzi, R., Dimitrov, D.M., Matope, S. et al. A case study on the design of a hot stamping tool with conformal cooling channels. Int J Adv Manuf Technol 114, 1833–1846 (2021). https://doi.org/10.1007/s00170-021-06973-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-021-06973-z