To Örebro University

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 (DP600) and 1.95 mm thick uncoated Docol 600DL (DP600). 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. 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 at Volvo Cars 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 at Volvo Cars 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 270,000 strokes without exhibiting any problems.