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LASER SURFACE-HARDENING OF DIES FOR CUTTING, BLANKING OR

TRIMMING OF UNCOATED DP600

Conference Paper · October 2004

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Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 169
October 5-6, 2004, Olofström, Sweden

L AS E R S UR F AC E - H AR D E N I NG O F DI E S FO R
C U TTI NG , BL AN K I N G O R TRI M M I NG O F U NCO ATE D D P6 00

Nader Asnafi, Tuve Johansson, Marc Miralles & Andreas Ullman

Volvo Cars Body Components, SE-293 80 Olofström, Sweden

ABSTRACT

In this study, the methods used to harden trim dies were at the focus. Laser surface-
hardening was compared to induction- and through-hardening for small and medium-size
series production. The sheet materials used were 1.2 mm thick uncoated Docol 600DP and
1.95 mm thick uncoated Docol 600DL. The die materials tested were Fermo, Carmo and
Sleipner.
This investigation showed that the optimum laser-hardening parameters must be
established for each trim die material. The trim die in laser-hardened Sleipner exhibits the
smallest wear, whilst the trim die in induction-hardened Fermo displays the largest wear in
the semi-industrial phase of this study. The magnitude of this largest wear is, however, very
small. The trim die in induction-hardened Fermo managed 100 000 strokes without any
problem. The dimensional changes after laser hardening are very small. The burr height is
very small, regardless of how the trim die is hardened.
In this study, two sets of production trim dies were manufactured and set up. This
production trim dies are used in the manufacture of V70 B-pillar Left and Right. Laser
hardening resulted in a lead time reduction by 5 labour days. However, the Tool & Die unit
estimates that the lead time reduction obtained with laser hardening should be around 10
days under normal conditions. The cost analysis conducted by the Tool & Die unit shows that
the manufacturing costs are reduced by 6%, if laser-hardening is selected. These production
trim dies are and will be monitored continuously. As this paper is being written, these dies
have been subject to 50 000 strokes.

INTRODUCTION

Fig. 1 displays the annual maintenance cost distribution per die type. As displayed in this
figure, the maintenance conducted on trim dies constitutes 74% of the total annual
maintenance costs. The trim dies are subject to maintenance due many different reasons.
However, re-sharpening of worn-out trim edges stands for 26% of the total annual
maintenance costs.

Draw dies Flange dies

8% 8%

Restrike dies
8%

Trim/
Restrike dies
2%
Trim dies
74%

Maintenance cost distribution per die type

Fig. 1. Annual maintenance cost distribution per die type.

Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 170
October 5-6, 2004, Olofström, Sweden

Trim edges wear out due to different reasons. The selected die material and/or hardening
method may not be appropriate for the sheet material (incl. its thickness) that is to be
trimmed. The sheet/die clearance is perhaps not correctly chosen or this clearance maybe
varies along the cut length.
The purpose of present investigation was to study
• how different trim die steels should be laser surface-hardened, and
• If laser surface-hardening of trim dies is more beneficial than the conventional hardening
methods – flame-, induction- and through-hardening.
in cutting/blanking/trimming of the sheet material DP600.
The principle of flame and induction hardening of a steel component is to quickly heat its
surface to the austenitic temperature range and then rapidly quench the component to
produce a martensitic structure on the surface layer.
In flame hardening the surface layer of steel is quickly austenitized by a high-temperature
flame (or a high-velocity combustion-product gas). Flame hardening can be applied by a
variety of methods – spot or stationary, progressive (progressive flame-hardening is
schematically displayed in Fig. 2), spinning, or a combination of progressive and spinning.
The quenching action after heating is accomplished by a combination of heat extraction by
the cold metal beneath the case and by an external quenching medium (water or oil
depending on the chemical composition of the steel and the targeted hardness).

Fig. 2. The principle of (progressive) flame-hardening, Fig. 3. The principle of induction hardening,
[1]. [1].

The basic components of an induction heating system are: (1) an induction coil, (2) an
alternating-current (AC) power supply, and (3) the workpiece itself. The coil is commonly a
copper tubing through which cooling water passes and takes a variety of shapes to suit the
part to be heated. The AC current flows through the coil, generates an electromagnetic field
that cuts through the workpiece, and which induces the eddy currents to heat the workpiece.
Induction heating of a steel part is accomplished by placing the part in a magnetic field
generated by high-frequency alternating current passing through a water-cooled copper
induction coil. This is shown in Fig. 3. The rapidly alternating magnetic field produced within
the coil induces current flow within the steel surface. The induced current within the steel
then produces heat according to the relationship heat = i2R, where R is the electrical
resistance of the steel. Different types of heating patterns can be produced by various types
of induction coils.
The depth of current penetration and hence depth of heating the metal surface depends
mainly on the frequency of the alternating current. The higher the frequency, the lower the
penetration. When shallow heating or a thin case is desired, high-frequency current is used.
Intermediate and low frequencies are used for applications requiring deeper case depths and
even through-hardening.
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 171
October 5-6, 2004, Olofström, Sweden

Steels for flame or induction hardening usually contain 0.4 to 0.75% carbon. The steel to
be flame- or induction-hardened is selected for both case and core properties. Since the core
structure is not affected by the surface treatment, the core properties must be developed by
proper heat treatment before the surface treatment. In general, a hard surface layer of
martensite is produced and a softer inner core that has a ferrite-pearlite structure.
Surface of Fe-C alloys can be hardened through a martensite structure by a moving laser
beam, provided the energy input, beam radius, and beam velocity are controlled within
certain limits. During laser hardening the surface of the work piece is exposed to the laser
beam. The absorbed radiation heats up the work piece locally. Movement of the laser across
the surface of the working piece produces hardened tracks.
The phase transformation induced by laser hardening for steels take the following stages:
1. Formation of austenite from pearlite-cementite (hypereutectoid steels) or pearlite-ferrite
(hypoeutectoid steels) aggregate structure
2. Martensite transformation from austenite
The high cooling rate (104 °C/s) in laser-hardening treatment exceeds the critical cooling
rate of martensite formation. The metallographic microstructure after laser hardening, which
determines the results of hardening, depends mainly on austenite formation in the thermal
cycle, and hence particular attention must be paid to the kinetic of its formation in a thermal
cycle.
Both heating and quenching stages of laser treatment can be described using classical Time-
Temperature-Austenitization and Time-Temperature-Transformation diagrams. See Fig. 4.

TTA diagram C60 Steel TTT diagram C60 Steel

Fig. 4. The principle of Laser surface-hardening, [1].

MATERIALS

Table 1 shows the chemical composition of the die materials tested in this study.
Uddeholm Tooling, Volvo Cars and Swedish and international designations for these die
materials are displayed in Table 2. Table 3 shows the normal delivery hardness, austenitizing
temperature and flame-hardening procedure for these die materials. The mechanical
properties of the sheet materials used in this investigation are displayed in Table 4.

Table. 1. The chemical composition of rolled bars of Fermo, Carmo and Sleipner, [2].
Material C Si Mn P S Cr Cu Al Mo Ni V
Fermo
Min (%) 0.46 0.30 0.80 - - 1.40 - 0.010 - - -
Max (%) 0.50 0.50 1,00 0.025 0.035 1.60 0.15 0.030 0.15 0.25 -
Carmo
Min (%) 0.57 0.20 0.70 - - 4.30 - - 0.40 - 0.15
Max (%) 0.61 0.50 0.90 0.025 0.005 4.70 0.25 - 0.60 - 0.25
Sleipner
Min (%) 0.82 0.7 0.38 - - 7.60 - - 2.40 - 0.35
Max (%) 0.97 1.1 0.62 - - 8.00 - - 2.60 - 0.55
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 172
October 5-6, 2004, Olofström, Sweden

Table 2. Uddeholm Tooling, Volvo Cars, Swedish and international designations, [2] & [3].
Uddeholm Volvo SS W.-Nr. AISI
Tooling Cars (Sweden) (Germany) (USA)
Fermo V-2247 - - -
Carmo V-2249 - 1.2358 -
Sleipner V-2263 - - -

Table 3. Normal delivery hardness, austenitizing temperature and flame-hardening procedure for the
die materials in this study, [3].
1)
Hardness Austenitizing
Material (HB) temperature (°°C) Flame-hardening
Fermo 250-290** 850 850 °C for flame-hardening. The surface
hardness will be 56 ± 2.
Consult also Uddeholm Tooling.
Carmo 240-270** 950-970 Hardness: surface 58 ± 2 HRC at a depth of 3-4
mm (400 HV10 kg).
Consult also Uddeholm Tooling.
Sleipner 235 950-1080 Cool freely in air.
The surface hardness will be 58-62 HRC and 41
HRC (400HB) at a depth of 3-3.5 mm.
Consult also Uddeholm Tooling.
1)
Normal delivery hardness
**
Hardened & tempered.

Table 4. Mechanical properties of the sheet materials tested in this study, [4].
Sheet Thickness Rp0.2 (MPa) Rm (MPa) A80 (%)
material (mm) min-max min-max min
Docol 600DL 1.95 280-(360) 600-700 20
Docol 600DP 1.20 350-(440) 600-700 16

EXPERIMENTAL PROCEDURES

Laboratory tests – optimization of the laser hardening process

All of the laser-hardening tests were carried out at

Duroc Application facilities located in the at Volvo
Cars area in Olofström. A high power diode laser of 4
kW (the heating source) adapted to a jointed-arm-
robot (6 axis KUKA robot) as guiding machine was
used. This equipment is shown in Fig. 5. A pyrometer
was used to measure (several times per second) the
temperature of the surface heated by the laser.
One of the purposes with these tests was to find
the optimum laser hardening parameters for each die
material. The following parameters affect the results
of laser hardening:
• The power distribution: the uniform power
distribution is more suitable than the conventional
Gaussian distribution. This uniform distribution,
displayed in Fig. 6, was used throughout this
investigation.
• The beam size and the lens: The lens allows
Fig. 5. Duroc Applications laser-
focusing or defocusing the laser beam in order to hardening facilities at Volvo Cars in
scan more or less large area. At Duroc Applicat- Olofström were used in this study.
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 173
October 5-6, 2004, Olofström, Sweden

Uniform
Guassian distribution
distribution

Fig. 6. Uniform power distribution was used in all tests.

ion facilities, two different lenses are available - the 8*8 mm lens and the 15*15 mm lens.
Both of these were tested.
• Temperature and laser power: The temperatures 1060 °C and 1070 °C were tested. In
Duroc's equipment, the temperature control is based on pyrometer measurements.
According to these measurements, the power of the laser is automatically adjusted to
reach the programmed temperature.
• The laser speed: The speed at which the robot moves the laser along the cutting edge. 5
mm/s is the speed Duroc normally selects in surface-hardening applications. Both 4
mm/s and 5 mm/s were tested.
• The laser angle: The angle formed between the laser beam and the cutting direction (the
plane vertical to the cutting edge), angle θ in Fig. 7. Angles 45°, 50° and 60° were tested.

Laser speed

Laser beam
Angle θ

Angle (90°°-θ
θ)

Bar

Fig. 7. Schematic illustration of the laser speed and laser beam angle.

• Coating: An absorbing coating is applied to the metal surface to avoid unnecessary

power loss by reflection. Practically, this was a black painting applied on the surface just
before laser processing.

Upper Movement of
the upper tool

X
X = Cutting direction
Lower
Y Y = Perpendicular to the cutting direction

Fig. 8. The value of hardness was investigated both along and perpendicularly to the cutting direction.
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 174
October 5-6, 2004, Olofström, Sweden

In cutting/blanking/trimming, the largest hardness depth as possible is required in the

cutting direction. That is since this side of the tool passes through the whole thickness of the
sheet material and, therefore, is subject to severe abrasion/adhesion. A large hardness
depth is also required perpendicularly to the cutting direction to assure a number of
regrinding/ polishing occasions (maintenance). During maintenance, typically 0.2-0.5 mm is
taken away. The above-mentioned directions are shown in Fig. 8.
Rolled bars of Fermo, Carmo and Sleipner were surface-hardened by laser at Duroc
Applications. Fig. 9 shows a rolled bar of Carmo surface hardened by laser with 8*8 mm and
15x 15 mm lenses, at the laser angles 45°, 50° and 60° and at 1060 °C. Note in Fig. 9 that
there is a distance between the hardened zones. This distance was kept at 10 mm in all
cases.
After laser hardening, samples were cut exactly at the middle of the hardened tracks.
These samples were then embedded in Bakelit, after which they were ground (1.2 mm was
removed from the surface) and polished (first to Ra = 9 µm and after washing with alcohol
down to Ra = 3 µm).
After sample preparation, the micro-hardness was measured along and perpendicularly to
the cutting direction in accordance with Fig. 10. Once the micro-hardness investigation was
carried out, the samples were etched with Nital (96% alcohol, 4% Nitric Acid) to study the
geometry of the heat-affected zone.

Length = 400 mm

Width =
63 mm Height =
50 mm

10 mm

Fig 9. A rolled bar of Carmo surface hardened by laser with 8*8 mm and 15*15 mm lenses and at the
laser angles 45°, 50° and 60°. Note that there is a distance of 10 mm between the hardened zones.

Hardened zone

0.5 mm

Cutting
direction

0.5 mm
Base material

Perpendicular to the
Cutting direction
Fig. 10. The micro-hardness was measured according to this figure.
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 175
October 5-6, 2004, Olofström, Sweden

Semi-industrial tests – die performance studies

A semi-industrial cutting/blanking/trimming tool per die material was manufactured and

used. Fig. 11 displays this tool in the case of Fermo. Two upper dies (per material) were, as
shown in Fig. 11, tested at the same time – one being induction-hardened whilst the other
being laser-hardened. The lower die in Fig. 11 was laser-hardened in all cases. The laser-
hardening was conducted with the optimum parameters found by the activities described in
the previous section.
The clearance between the upper and lower trim dies is one of the most important
parameters (if not the most important parameter) as far as wear, burr height, dimensional
tolerances and cut edge quality are concerned. This clearance should (as a rule of thumb) be
6-8% of the sheet thickness, if the ultimate tensile strength of the sheet material Rm < 450
MPa. However in case Rm > 450, the clearance should (as a rule of thumb) be 9-12% of the
sheet thickness.
If the clearance is too large or too small, the cracks will fail to meet. The tool wear
increases with a clearance which is tool small. The cutting force will also increase. A too
large clearance affects the geometry of the cut edge, with increased taper and larger rollover.
As mentioned above, a too small clearance increases the tool wear and the cutting force.
In this study, the clearance was therefore voluntarily set at 7% (of the sheet thickness) to
promote wear.

Semi-industrial tool
Upper plate Lower plate

Inserts

Laser- Induction- Laser-

hardened hardened hardened

The upper plate and the two inserts mounted on it. The two inserts mounted on the upper plate: Laser-
hardened Fermo in the foreground and induction-
hardened Fermo in the background.
Fig. 11. A semi-industrial cutting/blanking/trimming die was manufactured and used. Two dies were
tested at the same time – one being induction-hardened whilst the other being laser-hardened. The
photographs show the upper plate and the two Fermo inserts mounted on it.

The manufactured cutting/blanking/trimming tools (see Fig. 11 which shows the Fermo dies)
were set up in a mechanical press. In the performance tests, the press speed, the cutting
depth and the feed rate were kept constant at 55 strokes/min, 3 times the sheet thickness,
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 176
October 5-6, 2004, Olofström, Sweden

and 8 mm respectively. 1.2 mm thick Docol 600DP and 1.95 mm thick sheet of Docol 600DL
were used in these tests. See also Fig. 12.
Cutting tool

Cut pieces

1.2 mm thick Docol 600DP &

150 mm
1.95 mm thick Docol 600DL

8 mm
Fig. 12. A mechanical press was used. The clearance was set at 7% of the sheet thickness. The press
speed, the cutting depth and the feed rate were kept constant at 55 strokes/min, 3 times the sheet
thickness and 8 mm respectively. Note that the width of the cut pieces (strips) is exaggerated.

Initial profile

Profile after

Material loss

Limits of the square (0.1mm in side

length) for calculation of the surface
area between the two profiles

Fig. 13. To investigate the die wear (material loss) a high resolution (better than 6 nanometers)
profilometer was used. Ruby ball tip R = 0.5 mm was the stylus (the organ of the profilometer that is in
contact with the surface) used in this study. The initial and final profiles were measured by this stylus.
Autocad 2000 was then used to match these profiles and calculate the area difference between them.

To investigate the die wear (material loss) a high resolution (better than 6 nanometers)
profilometer was used. Ruby ball tip R = 0.5 mm was the stylus (the organ of the profilomet-
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 177
October 5-6, 2004, Olofström, Sweden

er that is in contact with the surface) used in this study. The initial and final profiles were
measured by this stylus. Autocad 2000 was then used to match these profiles and calculate
the area difference between them. This area was calculated in squares of 0.1 mm side length
centered exactly on the cutting edge angle as shown in Fig. 13.
To obtain a more comprehensive understanding of the wear (material loss) along the
cutting edge, the area difference (material loss) between the initial and final profiles was
measured at three different sections – 40, 90 and 99 mm from die side walls. This is
illustrated in Fig. 14. See also Fig. 13.

Sheet width 150 mm

Sheet

40 40
Laser- Induction-
hardened hardened 90 90

99 99

Fig. 14. The area difference (material loss) between the initial and final profiles was measured at three
different sections – 40, 90 and 99 mm from die side walls. See also Fig. 13.

As mentioned above, the sheet material was cut by two different inserts – one induction-
hardened and one laser-hardened – simultaneously. See, for instance, Fig. 14. This means
that the cut sheet metal strip had a side that was cut by the laser-hardened insert and a
second side that was cut by the induction-hardened insert. This is illustrated in Fig. 15. The
burr height was measured at the positions shown in Fig. 15. These measurements were
conducted in a optical microscope.

Measurement of Measurement of
the burr height the burr height

150 mm

Laser side Induction side 8 mm

20 mm 20 mm

Fig. 15. The cut sheet metal strip had a side that was cut by the laser-hardened insert and a second
side that was cut by the induction-hardened insert. The burr height was measured in an optical
microscope at both sides. See also Fig. 14.

Production tests – B-pillar/V70

The trim dies for B-pillar Volvo V70 were selected for a thorough investigation in this
stage. These dies were selected, since the trimming operation in stamping of this B-pillar
was assumed to be sufficiently demanding for industrial verification of laser surface-
hardening. Fig. 16 displays the B-pillar trim dies.
A tailor-welded (seam-welded) blank is used to stamp this B-pillar. This tailor-welded
blank consists of 1.95 mm thick Docol 600DL and 1.45 mm thick Rephos 260. Fig. 17 shows
the B-pillar before and after trimming. The trim dies in the encircled zone shown in this figure
were at the focus in this study.
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 178
October 5-6, 2004, Olofström, Sweden

B-pillar

Upper tool

Upper
trim steels

Lower
trim steels Lower tool

Upper trim die Lower trim die

Binder

Fig 16: The B-pillar (Volvo V70) trim dies were at the focus in this study.

Rephos 260,
Docol 600DL, 1.45 mm
1.95 mm

A B

Fig. 17. The B-pillar before (A) and after (B) trimming. This B-pillar is stamped in a tailor-welded
(seam-welded) blank comprising 1.95 mm thick Docol 600DL and 1.45 mm thick Rephos 260. The trim
die inserts used in the encircled zone in this figure were at the focus in this study.

Chipping and frequently occurring damages of different kinds were observed on the
existing trim dies for B-pillar V70. New trim die inserts were therefore manufactured in this
study. The existing trim dies were removed and the trim dies made in this study were
mounted on the tool. Fig. 18 displays the new trim dies for B-pillar Right and the alterations
made compared to the existing (old) trim dies.
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 179
October 5-6, 2004, Olofström, Sweden

Scrap trim

Common trim line – new trim dies

New (additional) trim line (new trim dies) vs. old trim line (old trim dies).

A Upper trim die.

B Lower trim die.
C The trim line (with the new trim dies) marked on the B-pillar.

Fig 18. The new trim dies and trim line for B-pillar Right (Volvo V70).

Rolled Sleipner was selected as die material, since it

• exhibited the best performance in the semi-industrial wear tests mentioned above and
• it is a new material at Volvo and therefore must be subject to different types of test
before verification/certification. Some of these tests were carried out in this study. See
below.
In this stage of the investigation, the following issues were studied (using the trim dies for
V70 B-pillar):
• How does a laser surface hardened trim die in Sleipner perform compared to a through-
hardened trim die in the same material (Sleipner)?
• How does a hardened, tempered and laser surface-hardened trim die in Sleipner behave
compared to an annealed and laser surface-hardened trim die in the same material
(Sleipner)?
In addition to the above-mentioned issues and since new trim dies were to be made, the
project team decided to study and compare the lead time and the manufacturing costs of
laser surface-hardened and conventionally hardened trim dies.
Two new sets of trim dies were manufactured – one set for V70 B-pillar Left and one for
V70 B-pillar Right – according to the following:
• B-pillar Left:
- Annealed (rolled) Sleipner is used.
- Upper trim die is split, as shown in Fig. 19.
- The die is through-hardened.
• B-pillar Right:
- Upper trim die is split, as shown in Fig. 19.
- Lower trim die is made in hardened and tempered (rolled) Sleipner.
- One of the trim steels in the upper trim die is made in annealed (rolled)
Sleipner, whilst the other steel in the upper trim die is made in hardened and
tempered (rolled) Sleipner. See Fig. 19.
- The die is surface-hardened by laser.
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 180
October 5-6, 2004, Olofström, Sweden

Hardened & tempered Annealed Hardened & tempered

Sleipner Sleipner Sleipner

Parting line

Mounting plate for the

upper trim die. Note
that the trim contour
is not milled yet at this
Lower trim die Upper trim die stage.

Fig. 19. The new trim die for V70 B-pillar Right was manufactured in this fashion prior to laser surface-
hardening.

The upper die was selected to be split, as shown in Fig. 19, to ease re-mounting and to be
able to study the hardening/tempering/annealing method mentioned above.
The trim die for B-pillar Left was through-hardened in the following fashion:
• Preheating to 856 °C, holding time ≈ 35 min.
• Austenitizing at 1056 °C, holding time ≈ 35 min.
• "Softening" at 1056 °C in 35 ≈ min. Cooling in ≈ 45 min.
• Slaking to room temperature, time ≈ 50 min.
• Annealing 1: temp. = 529 °C, time ≈ 2 hrs, slaking ≈ 2 hrs.
• Annealing 2: temp = 530 °C, time ≈ 2 hrs, slaking ≈ 2 hrs.
The ordered hardness was 63 HRC (≈ 770-780 HV).
Using the results of the laser surface-hardening optimization studies (see above), the new
trim die for V70 B-pillar Right was laser-hardened in the following manner (see also Fig. 20):
• Laser speed: in the yellow zone = 3 mm/s, in the red and blue zones = 4 mm/s, Fig. 20.
• Laser angle: in the red zone = 45°, in the yellow and blue zones = 60°. See also Fig. 7.
• The hardening direction is shown by the arrows in Fig. 20.
• Temperature = 1060 °C.

Yellow Yellow

Red

Lower trim die Upper trim die

Fig. 20. Laser surface-hardening of the new trim die for V70 B-pillar Right. The arrows show the
hardening direction. (In case the reader is seeing this figure in black and white: the trim die edges are
in blue, unless indicated by encircled zones).

RESULTS

Laboratory tests – optimization of the laser hardening process

Fig. 21 displays the hardness after laser surface-hardening versus depth for Fermo in
(top) and perpendicular (bottom) to the cutting direction. See also Figs. 8 & 10. The legend
shows the tested values of laser angle, lens size, temperature and laser speed respectively.
See also Fig. 7. Lower limit in Fig. 21 represents the minimum surface hardness required for
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 181
October 5-6, 2004, Olofström, Sweden

800

Fermo
700 In the cutting direction

600

Hardness (Hv)
500

400

300

200

100

0
0 1 2 3 4 5 6 7
Depth (mm)
45 degrees 15*15 1060 5mm/s 50 degrees 15*15 1060 5mm/s 60 degrees 15*15 1060 5mm/s
45 degrees 8*8 1060 5mm/s 50 degrees 8*8 1060 5mm/s 60 degrees 8*8 1060 5mm/s
Lower Limit

800

Fermo
700 Perpendicular to the cutting direction

600
Hardness (Hv)

500

400

300

200

100

0
0 1 2 3 4 5 6 7
Depth (mm)
45 degrees 15*15 1060 5mm/s 50 degrees 15*15 1060 5 mm/s 60 degrees 15*15 1060 5mm/s
45 degrees 8*8 1060 5mm/s 50 degrees 8*8 1060 5mm/s 60 degrees 8*8 1060 5mm/s
Lower Limit

Fig. 21. Hardness after laser surface-hardening versus depth for Fermo in the cutting direction (top)
and perpendicular to the cutting direction. See also Figs. 8 &10. The legend shows the laser angle,
lens size, temperature and laser speed respectively. See also Fig. 7. Lower limit in these figures
shows the minimum surface hardness required for trim dies (according to the project team).

trim dies, according to the judgment of the project team.

The 8*8mm lens is, as exhibited in Fig. 21, not suitable for laser surface-hardening. Using
this lens , the hardness decreases very rapidly at a depth of approximately 1.5 mm.
Perpendicularly to the cutting direction and with the 15*15 mm lens, the hardness is
almost the same down to a depth of approximately 2.2 mm regardless of the laser angle. In
the cutting direction and with the same lens, the best hardness profile is obtained with a laser
angle of 60°. Discussions with different involved parties (among them many practitioners)
showed that (see also Fig. 21):
• 2.2 mm in hardening depth in the perpendicular direction is sufficient to assure a good
cutting edge support and to allow a working window for maintenance (re-grinding and re-
polishing),
• the largest possible hardening depth should be selected in the cutting direction, and
• therefore, 60° in laser angle, the 15*15 mm lens, 1060 °C in temperature and 5 mm/s in
laser speed should be considered as the most optimum laser surface-hardening
parameters for Fermo. See Fig. 21 and Table 5.
Fig. 22 and 23 display the hardness after laser surface-hardening versus depth for Carmo
in (top) and perpendicular (bottom) to the cutting direction. See also Figs. 8 &10. The
legends in these figures show the tested values of laser angle, lens size, temperature and
laser speed respectively. See also Fig. 7. Lower limit in Figs. 22 & 23 show the minimum
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 182
October 5-6, 2004, Olofström, Sweden

800
Carmo
700 In the cutting direction

600

500
Hardness (Hv)
400

300

200

100

0
0 1 2 3 Depth (mm) 4 5 6 7
45 degrees 15*15 1060 5mm/s 50 degrees 15*15 1060 5mm/s 60 degrees 15*15 1060 5mm/s
45 degrees 8*8 1060 5mm/s 50 degrees 8*8 1060 5mm/s 60 degrees 8*8 1060 5mm/s
Lower Limit

800
Carmo
700 Perpendicular to the cutting direction

600
Hardness (Hv)

500

400

300

200

100

0
0 1 2 3 Depth (mm) 4 5 6 7
45 degrees 15*15 1060 5mm/s 50 degrees 15*15 1060 5mm/s 60 degrees 15*15 1060 5mm/s
45 degrees 8*8 1060 5mm/s 50 degrees 8*8 1060 5mm/s 60 degrees 8*8 1060 5mm/s
Lower Limit

Fig. 22. Hardness after laser surface-hardening versus depth for Carmo in the cutting direction (top)
and perpendicular to the cutting direction. See also Figs. 8 &10. The text in the legend stands for the
laser angle, lens size, temperature and laser speed respectively. See also Fig. 7. Lower limit in these
figures shows the minimum surface hardness required for trim dies (according to the project team).

surface hardness required for trim dies, according to the judgment of the project team.
The 8*8mm lens is, as exhibited in Fig. 22, not suitable for laser surface-hardening.
Focusing on the results obtained with the 15*15 mm lens (Figs. 21 & 22):
• the hardness falls almost directly (from the first millimeter) and there is no "hardness
plateau" as for Fermo. Compare Fig. 22 with Fig. 21.
• even with the 15*15 mm lens and the angle 60° (which yielded the best parameter
combination for Fermo), the hardening depth (the depth from the surface down to the
lower limit) is only 2.5 mm in the cutting direction, Fig. 22. The value of this depth was 3.2
mm for Fermo with the same laser hardening parameters, Fig. 21.
• the hardness falls down under 600 Hv after 1.5 mm in the perpendicular direction for
Carmo (Fig. 22) instead of 2.25 mm for Fermo (Fig. 21).
The questions is why Carmo behaves differently.
A comparison of the chemical compositions of Fermo and Carmo, Table 1, shows that the
major difference between these two materials is the Chromium content. In Carmo, the
maximum Chromium content is 4.70% whilst Fermo contains only 1.6% Chromium at the
maximum (Table 1).
It is very difficult to formulate any general rules regarding the influence of different alloying
elements. In this particular case, the Chromium is however believed to act according to the
following:
• Chromium increases the austenitization temperature.
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 183
October 5-6, 2004, Olofström, Sweden

900

800 Carmo
In the cutting direction
700

600

Hardness (Hv)
500

400

300

200

100

0
0 1 2 3 4 5 6 7
Depth (mm)
1070 C 4 mm/s 60 degrees 15*15 1060 C 4 mm/s 60 degrees 15*15
1060 C 5 mm/s 60 degrees 15*15 Lower limit

900

800 Carmo
Perpendicular to the cutting direction
700

600
Hardness (Hv)

500

400

300

200

100

0
0 1 2 3 4 5 6 7
Depth (mm)
1070 C 4 mm/s 60 degrees 15*15 1060 C 4 mm/s 60 degrees 15*15
1060 C 5 mm/s 60 degrees 15*15 Lower limit

Fig. 23. Hardness after laser surface-hardening versus depth for Carmo in the cutting direction (top)
and perpendicular to the cutting direction. See also Figs. 8 &10. The text in the legend stands for the
laser angle, lens size, temperature and laser speed respectively. See also Fig. 7. Lower limit in these
figures shows the minimum surface hardness required for trim dies (according to the project team).
Compare this figure (Fig. 23) with Fig. 22.

• During quenching, the temperature at which martensite begins to form (Ms) is

progressively lowered as the chromium content of the steel increases, as expressed by
the following empirical formula (Steven and Haynes):

Ms (°C)= 561 – 474 (%C) – 33 (%Mn) – 17 (%Ni) – 17 (%Cr) – 21 (%Mo)

• The only positive effect of Chromium for the hardening process is that Cr decreases
significantly the “critical cooling velocity” (equals the minimum cooling speed which will
produce martensite from austenite). But, one of the specifics of laser hardening is its high
cooling rate (up to 104 °C/s). This positive aspect of Chromium is, therefore, useless in
this particular situation.
To sum up, it is held that Chromium prevents austenite from forming and delays the start
of martensite formation. This can, in turn, explain the difference in laser surface-hardening
behavior between Fermo and Carmo displayed in Figs. 21 and 22.
To investigate the above-mentioned further, the laser speed and temperature were varied
whilst the laser angle was kept constant at 60° and the 15*15 mm lens was used in all cases.
The results of this investigation is shown in Fig. 23.
As displayed in Fig. 23, the results are improved with the new laser parameters both in
and perpendicularly to the cutting direction. The improvement is, however, most significant in
the cutting direction. Compare Fig. 23 with Fig. 22.
Using the results presented in Figs. 22 and 23, it is therefore held that 60° in laser angle,
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 184
October 5-6, 2004, Olofström, Sweden

800
Sleipner
700 In the cutting direction

600

Hardness (Hv)
500

400

300

200

100

0
0 1 2 3 4 5 6 7
Depth (mm)
60 degrees 15*15 1060 4mm/s 60 degrees 15*15 1060 5mm/s Lower Limit

800
Sleipner
700 Perpendicular to the cutting direction

600
Hardness (Hv)

500

400

300

200

100

0
0 1 2 3Depth (mm)4 5 6 7

60 degrees 15*15 1060 4mm/s 60 degrees 15*15 1060 5mm/s Lower Limit

Fig. 24. Hardness after laser surface-hardening versus depth for Sleipner in the cutting direction (top)
and perpendicular to the cutting direction. See also Figs. 8 &10. The text in the legend stands for the
laser angle, lens size, temperature and laser speed respectively. See also Fig. 7. Lower limit in these
figures shows the minimum surface hardness required for trim dies (according to the project team).

4 mm/s in laser speed, the 15*15 mm lens and 1060 °C in temperature constitute the best
set of parameters for laser surface-hardening of Carmo. See also Table 5.
The influence of Chromium and other alloying elements on the austenitization temperature
and critical cooling velocity was discussed above. See also the mathematical expression
above. In Sleipner, the chromium (and Molybdenum) content is larger than in Carmo, Table
1. In the laser surface-hardening tests carried out with Sleipner, It was therefore, decided to
• use the 15*15 mm lens and a laser angle of 60° (this combination gave the best results
for Fermo and Carmo).
• keep the "laser" temperature at 1060 °C.
• test different laser speeds: 4mm/s and 5mm/s. This speed appeared to have a major
impact on the results obtained with Carmo (compare Figs. 22 and 23).
Fermo and Carmo are normally hardened and tempered upon delivery, whilst Sleipner is
not. Sleipner displays therefore the lowest hardness upon delivery. See Table 3. In this
investigation, Sleipner was therefore hardened and tempered to 290 HB prior to laser
surface-hardening.
Fig. 24 displays the hardness after laser surface-hardening versus depth for Sleipner in
(top) and perpendicularly (bottom) to the cutting direction. See also Figs. 8 &10. The text in
the legend stands for the laser angle, lens size, temperature and laser speed respectively.
See also Fig. 7. Lower limit in Fig. 24 represents the minimum surface hardness required for
trim dies (according to the judgment of the project team).
The results obtained for Carmo (Figs. 22 and 23) and Sleipner (Fig. 24) suggested that it
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 185
October 5-6, 2004, Olofström, Sweden

might be possible to improve the hardness profile of Sleipner by reducing the laser speed
from 4 mm/s to 3 mm/s. Discussions with different parties (among them many practitioners)
showed that a reduction of the laser speed to 3 mm/s would result in severe dimensional
changes. It was therefore held that 60° in laser angle, 4 mm/s in laser speed, the 15*15 mm
lens and 1060 °C in temperature would be the optimum set of laser surface-hardening
parameters for Sleipner. See Fig. 24 and Table 5.

Table. 5. Optimum (yielding the best hardness profile) laser-hardening parameters found in this study.
Consult also Fig. 7.
Die Laser angle Laser speed Lens Temperature
material (°) (mm/s) (mm) (°°C)
Fermo 60 5 15 * 15 1060
Carmo 60 4 15 * 15 1060
Sleipner 60 4 15 * 15 1060

Semi-industrial tests – die performance studies

Semi-industrial trim dies were manufactured in Fermo, Carmo and Sleipner in accordance
with the procedure described above. See, for instance, Figs. 11, 12 & 15. The laser surface-
hardening of the dies was conducted using the optimum parameters given in Table 5.
Burr height was one of the parameters studied in this phase of the investigation. Fig. 25
displays the burr height versus the number of strokes for different die materials and
hardening methods - Fermo in combination with 1.2 mm thick Docol 600DP (top) and Carmo
and Sleipner both in combination with 1.95 mm thick Docol 600DL (bottom).

100

90 Sheet material = 1.2 mm thick Docol 600DP

80

70
Height (µm)

60

50

40

30

20 Fermo - Laser
10 Fermo - Induction

0
0 20000 40000 60000 80000 100000
Number of strokes

100

90 Sheet material = 1.95 mm thick Docol 600DL

80

70
Height (µm)

60

50

40

30 Sleipner - Laser
20 Sleipner - Induction
Carmo - Laser
10 Carmo - Induction
0
0 10000 20000 30000 40000 50000
Number of strokes

Fig. 25. Burr height versus number of strokes for different hardening methods: Fermo in combination
with 1.2 mm thick Docol 600DP (top) and Carmo and Sleipner both in combination with 1.95 mm thick
Docol 600DL (bottom).
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 186
October 5-6, 2004, Olofström, Sweden

0,004
Number of strokes = 50 000
Fermo - Laser
Fermo - Induction Sheet material =
0,003 1.2 mm thick Docol 600DP

Area (mm2)
0,002

0,001

0
40 90 99
Section position (mm)

0,004

Number of strokes = 50 000 Carmo - Laser

Carmo - Induction
0,003 Sheet material = 1.95 mm thick Docol 600DL
Area (mm2)

0,002

0,001

0
40 90 99
Section position (mm)

0,004
Sleipner - Laser Number of strokes = 50 000
Sleipner - Induction
Sheet material =
0,003
1.95 mm thick Docol 600DL
Area (mm2)

0,002

0,001

0
40 80 89
Section position (mm)

Fig. 26. Die wear expressed as material loss (area) versus section position for different hardening
methods after 50 000 strokes: Fermo in combination with 1.2 mm thick Docol 600DP (top) and Carmo
and Sleipner both in combination with 1.95 mm thick Docol 600DL (bottom). See also Fig. 13 and 14.

0,004
Fermo - Laser Sheet material = 1.2 mm
thick Docol 600DP
Fermo - Induction
0,003 Number of strokes = 100 000
Area (mm2)

0,002

0,001

0
40 90 99
Section position (mm)

Fig. 27. Die wear or material loss (area) versus section position for Fermo after 100 000 strokes.
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 187
October 5-6, 2004, Olofström, Sweden

As shown in Fig. 25, the burr height is very small after 100 000 strokes in a die made of
Fermo regardless of the selected (induction or laser hardening) surface hardening method.
The burr height is also very small after 50 000 strokes in a die made of Carmo or Sleipner.
The surface hardening method (induction or laser hardening) does not seem to have any
major impact.
Fig. 26 shows the die wear expressed in material loss (area) versus section position for
different hardening methods after 50 000 strokes – Fermo in combination with 1.2 mm thick
Docol 600DP (top) and Carmo and Sleipner both in combination with 1.95 mm thick Docol
600DL (bottom). Figs. 12-14 show how the die wear expressed as material loss (area) was
measured.
The smallest wear is, as exhibited in Fig. 26, obtained in the die that is made of Sleipner
and laser surface-hardened. Laser hardening appears to reduce the wear in Fermo and
Sleipner. However, it is not completely clear whether laser hardening or induction hardening
should be selected in the case of Carmo, Fig. 26.
To study how the die wear grows, the Fermo dies were allowed to go another 50 000
strokes. The Fermo die wear expressed in material loss (area) after 100 000 strokes is
displayed Fig. 27. A comparison of Fig. 27 and the top diagram in Fig. 26 shows that the die
wear has increased somewhat only at the section positions 40 & 90 mm (see also Fig. 14).
The dimensional changes before and after laser hardening were measured in a
coordinate-measuring machine. Fig. 28 shows the values obtained for the Fermo and Carmo
dies. The values obtained for the Sleipner die (which was somewhat shorter than the Fermo
and Carmo dies) are displayed in Fig. 29. As exhibited in these figure, the dimensional
changes are negligible.
The so-called corner and overlapping (overlapping of two laser tracks) issues were also
studied. For an account on these issues, the reader is referred to [1].

6
2
78 mm 3
5
1
2 6 38 mm
8 4
1 5

200 mm 4
UPPER 7 LOWER 200 mm

8
98 mm 70 mm 7

Upper die - Fermo Lower die - Fermo

No. Before (mm) After (mm) No. Before (mm) After (mm)
1 78.225 78.235 1 38.380 38.405
2 78.230 78.230 2 38.375 38.370
3 78.235 78.245 3 38.385 38.410
4 98.250 98.280 4 70.035 70.070
5 98.255 98.265 5 70.030 70.045
6 98.260 98.280 6 70.035 70.075
7 200.205 200.160 7 200.530 200.460
8 200.310 200.270 8 200.555 200.555
Upper die - Carmo Lower die - Carmo
No. Before (mm) After (mm) No. Before (mm) After (mm)
1 78.230 78.220 1 38.420 38.440
2 78.230 78.220 2 38.405 38.400
3 78.235 78.235 3 38.410 38.430
4 98.255 98.270 4 70.035 70.060
5 98.250 98.255 5 70.030 70.025
6 98.250 98.270 6 70.030 70.045
7 200.270 200.210 7 200.610 200.530
8 200.210 200.210 8 200.600 200.600
Fig. 28. The die dimensions were measured before and after laser hardening. This figure concerns the
Fermo and Carmo dies.
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 188
October 5-6, 2004, Olofström, Sweden

6
2
78 mm 3
5
1
2 6 38 mm
8 4
1 5

181 mm 4
UPPER 7 LOWER 171 mm

8
98 mm 70 mm 7

Upper die - Sleipner Lower die - Sleipner

No. Before (mm) After (mm) No. Before (mm) After (mm)
1 78.230 78.235 1 38.410 38.440
2 78.230 78.225 2 38.400 38.385
3 78.230 78.235 3 38.385 38.385
4 98.260 98.285 4 70.025 70.055
5 98.255 98.260 5 70.025 70.035
6 98.255 98.270 6 70.030 70.065
7 181.905 181.820 7 171.545 171.375
8 181.850 181.810 8 171.535 171.530
Fig. 29. The die dimensions were measured before and after laser hardening. This figure concerns the
Sleipner die.

Since laser-hardened Sleipner exhibited the smallest wear in the semi-industrial tests (Fig.
26) and since Sleipner is a new material at Volvo (new materials must be subject to different
types of tests before they are approved for introduction at Volvo), Sleipner was selected as
the die material for production tests. See the next section.

Upper die

Position 1

Position 3

Position 2
Lower die

Position 2

Position 1 Position 3

Stamped and trimmed part

Measured Position 1 Position 2 Position 3

clearance mm % mm % mm %
Laser hardened trim die (B-pillar Right) 0.10 5 0.40 21 0.30 15
Through-hardened trim die (B-pillar Left) 0.20 10 0.40 21 0.15 8
Fig. 30. Production tests: lower die, upper die and the measured clearance at three different positions.
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 189
October 5-6, 2004, Olofström, Sweden

Production tests – B-pillar/V70

In this stage, new trim dies were manufactured and set up in accordance with the
description above. To manufacture these new trim dies, the old trim dies were scanned. The
clearance was assumed to be 10%. As the new dies were manufactured and set up, the
clearance was measured. The results of these measurements is shown in Fig. 30.
As displayed in Fig. 30, the clearance varies along the trim line. To study the influence of
the clearance on the burr height and die wear, the project team decided to continue the
production tests without altering anything.
The burr height has been measured. Figs. 31 and 32 display the burr height versus the
number of strokes for through-hardened (V 70 B-pillar Left) and laser-hardened Sleipner
(V70 B-pillar Right) respectively. As exhibited in these figures, the burr height is acceptable.
Although a difference is noted between the through-hardened and the laser hardened trim
dies (Compare Fig. 31 to Fig. 32 at 13000 in number of strokes), it seems to be too soon to
draw any conclusions.
These dies are now and will in the future be monitored continuously. As this paper is
being written, both dies have managed 50 000 strokes without any problem.

160
Position 1 Through-hardened trim die
Position 2
120 Position 3
Height (µm)

80

40

0
0 5000 10000 15000
Number of strokes

Fig. 31. Burr height versus number of strokes. The figure concerns the through-hardened (Sleipner)
trim die – V70 B-pillar Left. See also Figs. 16-18.
160
Position 1
Position 2 Laser-hardened trim die
Position 3
120
Height (µ m)

80

40

0
0 5000 10000 15000 20000 25000
Number of strokes

Fig. 32. Burr height versus number of strokes. The figure concerns the laser-hardened (Sleipner) trim
die – V70 B-pillar Right. See also Figs. 16-20.

To study the lead time, the process chart for flame-, induction and through-hardening was
established. Laser hardening eliminates a number of operations on this chart:
• two transportation operations (that take 1 labour day totally),
• the final profiling/polishing after hardening (that takes 2 labour days), and
• Bottom spotting and other measures required after conventional hardening (which takes 2
labour days).
The lead time for the through-hardened trim die was 33 labour days, whilst the lead time
for the laser-hardened trim die was 28 labour days. The lead-time is, in other words,
Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 190
October 5-6, 2004, Olofström, Sweden

shortened by 5 days, if laser-hardening is selected. This project was, however, "ear-marked"

or given the highest possible priority. The Tool & Die unit estimates that the lead time
reduction obtained with laser hardening should be around 10 days under normal conditions.
The cost analysis conducted by the Tool & Die unit shows that the manufacturing costs
are reduced by 6%, if laser-hardening is selected.
For a more detailed description of the results obtained in this stage, the reader is referred
to [5].
As mentioned above, the dies are and will be monitored continuously. (As this paper is
being written the dies have been subject to around 50 000 strokes).

CONCLUSIONS

The following conclusions apply:

• The optimum laser-hardening parameters must be established for each trim die material.
The optimum parameters found in this study are presented in Table 5.
• The trim die in laser-hardened Sleipner exhibits the smallest wear, whilst the trim die in
induction-hardened Fermo displays the largest wear in the semi-industrial phase of this
study. This largest wear is, however, very small. The trim die in induction-hardened
Fermo managed 100 000 strokes without any problem.
• The dimensional changes after laser hardening are very small and negligible.
• The burr height is very small, regardless of how the trim die is hardened.
• In this study, laser hardening resulted in a lead time reduction by 5 labour days. However,
the Tool & Die unit estimates that the lead time reduction obtained with laser hardening
should be around 10 days under normal conditions.
• The cost analysis conducted by the Tool & Die unit shows that the manufacturing costs
are reduced by 6%, if laser-hardening is selected.
• The production trim dies are and will be monitored continuously.

REFERENCES

1. Marc Miralles: "Laser hardening of cutting tools", Master Thesis, Luleå University of
Technology, 2003.
2. Volvo Cars die material standards.
3. Uddeholm Tooling - fickhandbok (in Swedish).
4. Swedish Steel - Forming Handbook (in Swedish).
5. Andreas Ullman: "Industrialisering av laserhärdade klippstål samt utvärdering av
laserhärdning kontra konventionell härdning", Master Thesis, Lund Institute of
Technology, 2004 (in Swedish).
 Recent Advances in Manufacture & Use of Tools & Dies and Stamping of Steel Sheets 191
October 5-6, 2004, Olofström, Sweden

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