Digital Foundry Technology Research For Automobile Hot Stamping Die

High-strength steel to replace the traditional steel can reduce automobile body weight and improve crash safety, then achieve automobile lightweight. Different with traditional steel, the forming of high-strength steel need hot stamping die with internal conformal cooling channels. Successful forming of the internal conformal cooling channels is the focus of hot stamping die manufacturing. There are drilling method、inlaying method、advanced buried casting method and ceramic core casting method to form conformal cooling channels. These processes each have distinct characteristics, but in the actual production, there are some drawbacks.A digital foundry technology was proposed for automobile hot stamping die such a complex cavity structure casting. Casting simulation technology was used to complete casting process design, Rapid Prototyping was used to manufacture the casting mold, die casting blank was obtained by pouring the combined casting mold,3-D scanning technology was used to make accuracy test for products obtained in each step.Foundry process design is the basic process in the whole technology route. Foundry design was proposed on the basis of the structure and the shape of the hot stamping die. Procast simulation software was used to put forward optimization according to the simulation results.Separation type design of mold was proposed according to corresponding casting program. Each casting mold was manufactured by SLS RP equipment. Processing casting mold by RP is the core of the route. Molybdenum wire as bone was added in sand core to improve the high temperature strength to increase the success rate of the channels fully formed, which is the focus of the route.Pouring was the closest part in the entire route to the traditional casting process, but precision hot stamping die blank was got due to RP manufactured mold and optimization guidance.3-D scanning technology was used to scan for products obtained in each step, then accuracy evaluation results was acquired by comparison between the scan point cloud and designing prototype. Better quality products was obtained by design and manufacturing process optimization according to the feedback accuracy evaluation results.