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Final report on Contract no. 7210-PR/105, 1 July 1998 to 31 December 2001

Low-cost solutions to expensive automotive manufacturing processes need to be found. The effect of various low-cost tooling/coated steel combinations on forming, wear and durability has been studied. Four low-cost materials were tested: plastic, wood, Ni-shell and Kirksite, in addition to cast iron. Three types of steel were used, galvanneal, galvanised and electrozinc. Stamping trials were used alongside laboratory wear testing to assess the lifetime of the tooling materials. Formability test were used to assess their effect on the forming process.

The effects of tooling are dependent upon the type of zinc coating used. Compared to cast iron, the forming window was reduced for many of the low-cost tooling/sheet combinations. However, some combinations, particularly Ni-shell and Kirksite with galvanneal. Modelling the forming process using low-cost tooling has been successful.

For Ni-shell material, very low wear was measured and, with the right combination of sheet material and lubricant, it has potential to be used for medium to high value production. Kirksite gave good formability with all sheet materials tested and this may allow complex parts to be formed more easily than with a cast iron tool. Plastic and wood generally displayed the lowest formability.

Additional information

Authors: ELLIOTT L J, Corus, IJmuiden (NL);BOLT P J, TNO Industrie, Eindhoven (NL);BURIAT M, Usinor, La Défense (FR);LABELLARTE A, CSM, Rome (IT)
Bibliographic Reference: EUR 20319 EN (2002), pp.117. Euro: 17.50
Availability: EUR-OP reference: KI-NA-20319-EN-S Available from EUR-OP sales agents. URL:
ISBN: ISBN: 92-894-3653-0
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