Page i

Table of Contents
1.

Introduction ........................................................................................................................ 1
1.1

2.

HPF Review ................................................................................................................ 2

HPF processes and technology ........................................................................................... 3

2.1 Laser Cutting process ....................................................................................................... 3
2.2 Hard cutting process ........................................................................................................ 3
2.3 Warm Cutting Process ..................................................................................................... 3
2.4 Forming Process............................................................................................................... 3
2.4.1 Cold Forming ............................................................................................................ 4
2.4.2 Warm Forming .......................................................................................................... 5
2.4.3 Hot Forming .............................................................................................................. 6

3.

Conclusion ....................................................................................................................... 10

4.

References ........................................................................................................................ 11

Page ii

1. INTRODUCTION

The uses of hot stamping technological processes in forming almost all types of parts is
becoming more and more robust as industries looking forward for easy and flexible
manufacturing. Hot Press Forming (HPF) consists of the press forming and moves onto the
cooling of the press form parts within the die technology. Nowadays, hot stamping, hardening
and forming are integrated as a single process leading to both direct and indirect methods.
The direct method however enables heating of the raw material (iron, steel or iron-based
metal) to a specified temperature between 900 to 950 degree Celsius and about ten minutes in
a furnace and transfer to a cooled dies between 50 to 100 degree Celsius per second while the
overall time taken for stamping and cooling is about 15 to 25 seconds. At the other hand,
indirect stamping method requires part to be drawn using 3-D software like Cad/Cam
whereas the final shape requires partial trimming after the process pass through a
conventional dies heated to approximately 95%, also the forming process in material data lies
in between 600-900 degree Celsius.
Many researcher has successfully contributed to the technology of HPF among these are
[16-17, 26, 31, 34] focused on HPF design and simulation [20, 21] concentrated on
experiment and measurement, [24] design of boron steel for HPF without cooling system,
[25] design with heated and cooled tooling, [27] Design of hot V-bend test for boron steel
heating and forming process, [30] design of high vehicle strength steel by the influence of
HPF, [28] design of hot stamping vehicle door beams, [29] presented improvement of hot
press stamping formability design, [33] design for metal forming. The advancement of this
technology has been a proven factor for sustainability as discussed in the paper of [38] and
more effort about the overall HPF process was demonstrated in [40]. This report however
focuses on the HPF process cycle in forming almost all parts, the process and the
technologies employed into the system will be presented in more details in the group
presentation.

Page 1

1.1

HPF Review
Hot press forming was review in 2010 by [4] looking at the areas of mechanical,

thermal, technological and microstructural of hot stamping. The study shows great potential
for innovation and further investigations of hot sheet metal forming. An early study by [9]
investigated the design for HPF process to manufacture automotive plate found that the
indirect approach which involve pre-forming phase and the direct oil quenching to achieve
uniform and rapid cooling rate. More recent work conducted by [10] investigating the design
of the cooling channel for HPF specifically for hot stamping tools to achieve a uniform
component were finalized with an evidence of experimental design founded out that in order
to maintained a uniform components, energy balance principle is required with a critical
calculation using sophisticated measurement device. Moreover [11] studied how to
minimized the cooling time which will facilitate the cooling efficiency and maintain a high
uniformity simply by improving the dimensions of the cooling channel whereas [12] tends to
developed a model that will quench cooling time by introducing easy calculations by
considering thermal conductivity as a benchmark for the analysis of the tool material, the
temperature of the cooling water part as well as the velocity while at the other hand [18]
developed 3D Finite Element (FE) numerical model for thermo-mechanical-based hot press
stamping by investigating the effect of two processing parameters of tool punch speed on the
final properties and temperature of hot stamped component, [19] critically analysed the effect
of elastic plastic phase transformation during HPF, [22] using FE to investigate non-quadratic
anisotropic function and nonlinear kinematic hardening in the plasticity transformation during
HPF was fully discussed. Furthermore [13] designed an optimal cooling system for HPF to
improve the efficiency of quenching during hot stamping of high-strength boron steel over
thermal evaluation and analysis, similarly [35] worked on hot press stamping optimization
while [36] Smart hot stamping processes. The importance and the usefulness of simulation
for forming and forging was detail described in [14-15] using Computer-aided
design/Computer-aided engineering CAD/CAE technology as well as Process-Chain
Simulation-System to study the material behaviour in real world analysis.

Page 2

2. HPF PROCESSES AND TECHNOLOGY

Conventional sheet metal forming process chain after forming, piercing or cutting is the
next stage in hot stamping. The process are discuss in this section
2.1 Laser Cutting process
It has been proved by [5] that laser cutting is the most famous used process for cutting
hot stamped parts due to the high strength of the material after hot stamping and the fact that
it does any failure on the cutting edge in contrast to traditional cutting process that requires
contact trimming and tool wear. Further advantage shows that the use of laser has no limits to
the shape of the parts to be trimmed or cut.
2.2 Hard cutting process
Because of the high tensile strength of the press-hardened parts leads to severe tool
wear in the blanking process whereby the quality of the dimension precision and the sheared
surface are influenced by certain development parameters, such as blanking angles, punch
speeds, punch-die clearances, the mechanical properties of the material as well as the tool
cutting edge geometries. Further analysis of the hard cutting process was investigated by [6]
founded that the high hardness of punch-die prompts the use of low wear cutting edge, hence,
at some point in time it become more and more sensitive to high load because of the microfractures which is likely to occur at the cutting edge. Similarly at a high-toughness of the
punch induces small amount of reduction of wear resistance at the cutting edge. The cutting
process of hard press cutting part according to [7] argued that the optimum high-toughness is
compromise to advance the mechanical performance of tools
2.3 Warm Cutting Process
Warm cutting process is another alternative method deployed in hot stamped parts.
This process occurs at the cutting of parts during quenching at higher temperatures. The
benefits of this process enable quenching cutting force which will result in optimized cutting
edge over a short process sequence. In order to avoid a very hard for of steel transformation,
the cooling degree in the cutting areas must be quenched.
2.4 Forming Process
The blank should be transfer as fast as possible from the furnace of the hot press in
order to avoid part cooling before forming. Again this process must finish before
commencing the hard part of the steel crystal structure (martensite) transformation. This

Page 3

implies that a very fast object like the programmed robot arm is an ideal for a successful
forming process control. The closed tool is responsible for quenching the part immediately
after forming which will be cooled by water ducts in order to evacuate the hot heat from the
tool system.
2.4.1 Cold Forming
Cold forming begin at normal room temperature which is characterized by forming of
the work piece whereby there is no external heating require during this process. There are two
commonly known types of cold forming processes called upsetting and extrusion. The
upsetting process which described the manufacturing processes in greater details for instance
an open die as an example of upsetting whereby the work-piece dimensions lies between
parallel or flat effective surfaces. At the other hand extrusion is the act of pushing through
work-piece between two compactible tool parts which can be a rigid tools or active media
extrusion. The following figures illustrated the upsetting and extrusion.

Images of cold forming product [32]

Figure 1: Upsetting and partial upsetting Process [32]

Page 4

Figure 2: Classification flow chart of Extrusion Processes [32]

2.4.2 Warm Forming

At the very beginning of the blank temperature, the warm forming lies in between
cold forming and hot forming. The benefits of cold forming such as close tolerances, strain
hardening and high surface qualities tends to achieve higher true strain, when comparing
warm forming with hot forming, the yield stresses are found to be 3 times greater and the
desired true strain is lower. Below shows an image of warm forming

Images of warm forming product [32]

Page 5

Manufacturing Forming processes [32]

2.4.3 Hot Forming

The manufacturing through forming a work-piece using separating, heating and
joining refers to as forging whereas tensile forming, compressive forming processes, shear
forming processes, bend forming and rolling processes, the different mixtures of which
constitute various process alternatives or manufacturing sequences refers to as hot forming as
described below. This can be classified into open and close die forging. Experimented result
and simulated result of forging is given by [37].

Page 6

Images of open and close die forging

Page 7

2.5 Comparing Hot-stamping technology to conventional technology

Comparing the traditional cold formed parts, the new highly developed hot stamp parts
provides better stamping shape at a very high temperature, the conventional cold stamping
approach and micro-alloyed boron steel can be processed with non-isothermal hot sheet metal
forming process further known as direct hot-stamping. However, the modern technological
process conglomerates hot forming and simultaneously satiate hardening in a single operating
process. The following attributes advantages over the traditional technology for producing
parts
High material tensile strength
Reduction of weight/reduction of material sheet thickness (50%)
Hot stamping is compatible with boron-alloyed steels chemical composition,
Hot-stamping technology can be used to manufacture complex and sophisticated parts
such as house roof nails, car bumpers and pillars/beams reinforcement

Page 8

HPF Process Cycle [39]

Hot stamping process of Boron 22MnB5 diagram [39]

Page 9

3. CONCLUSION

Finite Analysis helps to overcome one of the greatest weaknesses in hot stamping
technology when the cooling temperature distribution is not insufficient which can lead to
poor part performance. Furthermore, the manufacturing process of thermo-mechanical or
steels boron treatment go through hot rolling of furnace and then to a low quench-able
temperature and lastly, produce a very good structural homogeneity whereby leading to a
good response of mechanical stress. The HPF technology is an alternative method for
reducing computational time for the realistic mechanical and thermal phenomena in the
production of parts through hot forming process. Hence, the development of simulation using
3D-software to be embedded into the hot stamping tends to reduces overall time wastage in
the production process and therefore facilitate parameters optimization.
Input blank
material
(Blank Tem (Tb))

Start
End
EMM5702
GS 38235
GS 37432
GS 37433

Det. Cycle time

No

Det. The tool surface tem (Ts)

Det. The diameter of the cooling

channel

Yes

Tmax-Tmin>Tallowance

No

Yes
No

Ve>=10,000
Cal. The velocity of the cooling
water (Ve)

Tb>Ts
of the blank after cooling
process

Yes
Cal. the number of cooling
channel (n)

Split tool to increase cooling

performance & machinability

Cooling analysis & thermal

analysis

Arrange the cooling channel at

2D section by triangular method

Flow chart process of HPF

Page 10

Connect the cooling channel

4. REFERENCES

[1] Taylan Altan. 2006. Hot-stamping boron-alloyed steels for automotive parts, Part I:
Process methods and uses. Stamping Journal: An FMA Publication
[2] Taylan Altan. 2007. Hot-stamping boron-alloyed steels for automotive parts, Part II:
Microstructure, material strength changes during hot stamping. Stamping Journal: An FMA
Publication.
[3] Taylan Altan. 2007. Hot-stamping boron-alloyed steels for automotive parts, part 3: Tools
Design and Process simulation. Stamping Journal: An FMA Publication
[4] Karbasian, H., Tekkaya, A.E. 2010. A review on hot stamping. Elsevier Journal of
Materials Processing Technology 210, 21032118
[5] Kolleck, R., Aspacher, J., Veit, R., 2009. Efficienty of hot forming processes. In: 2nd
International Conference on Hot Sheet Metal Forming of High-Performance Steel, Lulea,
Sweden, pp. 173179.
[6] So, H., Hoffmann, H., Golle, R., 2009. Blanking of press hardened ultra high strength
steel. In: 2nd International Conference on Hot Sheet Metal Forming of High- Performance
Steel, Lulea, Sweden, pp. 137145.
[7] Picas, I., Hernndez, R., Casellas, D., Negona, C., Valls, I., 2008. Tool performance in
cutting of hot stamped steels. In: 1st International Conference on Hot Sheet Metal Forming of
High-Performance Steel, Kassel, Germany, pp. 179189
[8] Kolleck, R., Veit, R., Merklein, M., Lechler, J., Geiger, M., 2009b. Investigation on
induction heating for hot stamping of boron alloyed steels. CIRP AnnalsManufacturing
Technology 58, 275278
[9] Myoung-GyuLee, Sung-Joon Kim, Heung, N.H., Woo, C.J. 2009. Application of hot
press forming process to manufacture an automotive part and its finite element analysis
considering phase transformation plasticity. International Journal of Mechanical Sciences
51(1)888898
[10] Woo-Seung Lim & Hong-Seok Choi & Seok-young Ahn & Byung-Min Kim. 2013.
Cooling channel design of hot stamping tools for uniform high-strength components in hot
stamping process. Springer-Verlag London Int J Adv Manuf Technol 70:11891203
[11] Average tensile strengths of roof side products manufactured with the cooling times of
12 and 9 s were 1,487 and 1,488 MPa, respectively. Average hardness values of roof side
products were Hmv 508 and 504.4, and standard deviations were 10.1 and 5.3. These values
satisfy the evaluation criteria
[12] The design method proposed in this paper was verified by means of cooling analysis and
hot stamping experiments and can be applied to other hot stamping tools.

Page 11

[13] Hongsheng, L., Chengxi, L., Zhongwen, X., 2013. Cooling system of hot stamping of
quenchable steel BR1500HS: optimization and manufacturing methods. Springer-Verlag
London Int J Adv Manuf Technol (1) 69:211223
[14] Saman, K., Abdolrahman, D., Taher, A. Mohammad, H.S. 2011. Design and
manufacturing of a straight bevel gear in hot precision forging process using finite volume
method and CAD/CAE technology. Springer-Verlag London Limited Int J Adv Manuf
Technol (1) 56:8795
[15] Bariani,P. F., Bruschi, S., Ghiotti, A. 2010. Critical issues in the simulation of hot
forming operations. Journal of German Academic Society for Production Engineering
(WGP); Prod. Eng. Res. Devel. (1) 4:407411
[16] Hoffmann, H., So, H., Steinbeiss, H. 2007.Design of Hot Stamping Tools with Cooling
System. Eselvier Journals of Annals of the CIRP Vol. 56/1
[17] Hyunwoo, So., Hartmut, H., Design of Hot Stamping Tools and Blanking Strategies of
Ultra High Strength Steels. Technische Universitat Munchen, Department of Mechanical
Engineering, Munich, Germany
[18] LIU, W., LIU, H-S., XING, Z-W, LIU, G., BAO, J. 2012. Effect of tool temperature and
punch speed on hot stamping of ultra-high strength steel.Elsevier Journal of Trans.
Nonferrous Met. Soc. China 22(1) 534541.
[19] Lee, M-G., Kim, S-J. 2012. Elastic-Plastic Constitutive Model for Accurate Springback
Prediction in Hot Press Sheet Forming. Journal of KIM and Springer, Met. Mater. Int., Vol.
18, No. 3 (1), pp. 425-432
[20] Etienne, J.F.R., Kyle, J.D., Mary, A.W. 2014. Experimental heat transfer coefficient
measurements during hot forming die quenching of boron steel at high temperatures. Elsevier
International Journal of Heat and Mass Transfer 71(1) 396404
[21] Abdulhay, B., Bourouga, B., Dessain, C., Brun, G., Wilsius, J. 2009. Experimental
Study of Heat Transfer in Hot Stamping Process. Springer Int J Mater Form (2009) Vol. 2
Supply 1:255257
[22] Lee, M-G., Kim, S-J., Heung, N.H. 2009. Finite element investigations for the role of
transformation plasticity on springback in hot press forming process. Elsevier Journal of
Computational Materials Science 47 (1) 556567
[23] Jang, J-H., Lee, J-H., Joo, B-D., Moon, Y-H. 2009. Flow characteristics of aluminum
coated boron steel in hot press forming. Elsevier Journal of Trans. Nonferrous Met.Soc.
China 19(1) 913-916
[24] LIU, H-s., XING, Z-W., LEI, C-X. 2012. Hot formation quality of high strength steel
BR1500HS for hot stamping without cooling system. Elsevier Journal of Trans. Nonferrous
Met.Soc. China 22(1) 542-547

Page 12

[25] George, R., Bardelcik, A., Worswick M.J. 2012. Hot forming of boron steels using
heated and cooled tooling for tailored properties. Eslevier Journal of Materials Processing
Technology 212 (1) 2386 2399
[26] Chao, J., Zhongde, S., Bailiang, Z., Milan, Z., Ying, X. 2012. Hot Stamping Die Design
for Vehicle Door Beams using Ultra-High Strength Steel. International Journal of Precision
Engineering and Manufacturing Vol. 13, No. 7, pp. 1101-1106
[27] Masahiro, N., Koji, A., Masaru, T., Hiroshi, T., Kazuhito, I., Toru, T., Nobusato, K,.
2013. Springer-Verlag Berlin Heidelberg
[28] Shan, Z-d., Ye, Y-S., Zhang, M-L., Wang, B-y. 2013. Hot-Stamping Die-Cooling
System for Vehicle Door Beams. KSPE and Springer International Journal of Precision
Engineering and Manufacturing Vol. 14, No. 7, pp. 1251-1255
[29] Tomoyoshi, M., Mori, K-I., Takaaki, N. 2014. Improvement in formability by control of
temperature in hot stamping of ultra-high strength steel parts. Elsevier Journal of CIRP
Annals - Manufacturing Technology, CIRP-1116; 1-4
[30] Chang, Y., Meng, Z-H., Ying, L., LI, X-D., Ning, M., Ping, H. 2-11. Influence of Hot
Press Forming Techniques on Properties of Vehicle High Strength Steels. ScienceDirect
Journal of Iron and Steel Research, International. 2011, 18(5): 59-63
[31] Chengxi, L., Junjia, C., Zhongwen, X., Hongya, F., Hao, Z. 2012.Investigation of
Cooling Effect of Hot-stamping Dies by Numerical Simulation. Physics Procedia 25(1) 118
124
[32] Klocke, F. 2013.Manufacturing Processes for RWTH edition, DOI: 10.1007/978-3-64236772-4_3. Springer-Verlag Berlin Heidelberg
[33] Osakada, K., Mori, K., Altan, T., Groche, P. 2011. Mechanical servo press technology
for metal forming. Elsevier Journal for CIRP Annals - Manufacturing Technology 60 (1)
651672
[34] Zhuang, B-L., Shan, Z-D., Jiang, C.C, Rong, W-J. 2010. Numerical Simulation of hot
Stamping Technology for Automotive Structural Parts. International Conference on
Advanced Technology of Design and Manufacture
[35] Jing, Z., Baoyu, W., Jianguo, L., Lei, F. 2013 Optimization of an Aluminium-alloy anticollision side beam hot stamping process using a multi-objective genetic algorithm Elsevier
archives of civil and mechanical engineering 13(1) 401411
[36] Mori, K-I. 2012. Smart hot stamping of ultra-high strength steel parts. Trans. Nonferrous
Met. Soc. China 22(1) 496503
[37] Hu, C-L., Li, W., Zhen, Z., Zhang, H-Y, Wang, Y-H. 2010. Study on Precision Forging
Process of Spur gear in Parking Brake. International Conference on Advanced Technology of
Design and Manufacture 2010

Page 13

[38] Ingarao, G., Lorenzo, R.D., Micari, F. 2011. Sustainability issues in sheet metal forming
processes: an overview. Elsevier Journal of Cleaner Production 19 (1) 337-347
[39] Erman, A.T, Karbasian, H., Werner, H., Matthias, K. 2007. Thermo-mechanical coupled
simulation of hot stamping components for process design. Prod. Eng. Res. Devel. (1) 1:85
89
[40] Katsuyoshi, I., Jun, Y. 2011. Valuation method for effects of hot stamping process
parameters on product properties using hot forming simulator. Elsevier Journal of Materials
Processing Technology 211 (1) 14411447

Page 14