Key Engineering Materials Submitted: 2021-11-28

ISSN: 1662-9795, Vol. 926, pp 645-654 Revised: 2022-01-31

doi:10.4028/p-5kczh8 Accepted: 2022-02-08
© 2022 The Author(s). Published by Trans Tech Publications Ltd, Switzerland. Online: 2022-07-22

Influence of Conformal Cooling Channel Parameters on Hot Stamping

Tool and Press-Hardening Process
Maria Emanuela Palmieri1,a*, Luigi Tricarico1,b
1
Politecnico of Bari (Department of Mechanical Engineering, Mathematics & Management
Engineering), 70125 Bari (Italy)
a
[email protected], [email protected]

Keywords: Hot stamping tool, Conformal cooling channel, design optimization, Finite Element analysis

Abstract. Press hardening is a technology increasingly used in the automotive industries to produce
high-strength structural parts in boron steel. The part strengthening is due to a martensitic
microstructure, which is obtained during the quenching phase of the process by imposing cooling
rates typically higher than 27 K/s. To improve cooling efficiency, conformal cooling channels (CCC)
are increasingly adopting thanks to opportunities offered by additive manufacturing (AM)
technologies in combination with the development of powders with high thermal conductivity.
In this work a methodology for the design of CCC inside hot stamping tools is presented and the press
hardening of an automotive B-Pillar in 22MnB5 has been used as case study. The proposed
methodology provides for an optimization of the distance between the cooling channels (p) and
distance between the tool surface and the cooling channel center (d).

Introduction
Press-Hardening process is a technology increasingly used in the automotive industries to produce
high-strength structural parts in Advanced High Strength Steels (AHSS). During this technological
process the blanks are initially heated above the complete austenitization temperature Ac3, then the
blanks are formed and cooled in closed tools to quench the material [1]. The high mechanical strength
of the part is guaranteed thanks to the quenching phase during which a martensitic transformation
occurs. However, the fully martensitic microstructure is obtained for cooling rate greater than 27 K/s
approximately and for a tool temperature below 200 °C [1-3]. To attain this, a production of tools
with cooling system is required. In general, the cooling system consist of drilled channels in which
water circulates [2,4]. An efficient design of the cooling system is desired in order to reduce the
cooling time of the process and allow a uniform distribution of cooling. In fact, reducing the cooling
time by means of an increase of the cooling rate, the total cycle time is reduced [5]. Moreover, the
need to have a uniformly cooled part arises from the need to avoid dimensional discrepancies [6-7].
To meet these requirements, most of scientific works are mainly focused on optimizing cooling
channel diameter, the distance between channels and the distance between tool surface and channel.
Shan et al. [8] showed that the depth from the die surface to the cooling channels has the biggest
impact on the cooling rate and uniformity of the workpiece. Moreover, they discovered that
augmenting the cooling channel diameter near the inlet improved the water flow uniformity. Lin et
al. [9] showed that the distance between the cooling channels and the distance between the cooling
channel and the tools surface have significant influence on the quenching effect; in particular better
quenching effect can be achieved with the shorter distance from the tool surface and with smaller
distance between cooling channels. Furthermore, thermal expansion proved to be the main reason for
deformation of the hot forming tools, which causes the distortion of the cooling channels, and the
stress concentration at corner of the cooling channels. Recently, Hung et al. [10] stated that the blank
thickness, the distance from the tool surface to the cooling channel edge, and distance between
cooling channel edges are the parameters that have marked effects on cooling performance. These
studies mentioned so far are mainly focused on straight drilled channels, however to improve cooling
efficiency, conformal cooling channels (CCC) are increasingly adopting thanks to opportunities
offered by additive manufacturing (AM) technologies in combination with the development of
powders with high thermal conductivity. Cortina et al. [11] investigated the design and manufacturing

This article is an open access article under the terms and conditions of the Creative Commons Attribution (CC BY) license
(https://creativecommons.org/licenses/by/4.0)
646 Achievements and Trends in Material Forming

of conformal cooling ducts via additive manufacturing and they compared the conformal cooling
conduits with the traditional straight channels. With regard to thermal results, a more homogeneous
temperature distribution within the tool and the stamped part is attained with CCC, leading to the
enhancement of the dimensional accuracy and features of the produced parts. Moreover, they stated
that better temperature distribution also leads to the lowering of the process cycle times in hot
stamping and the subsequent improvement of the efficiency of the process and reduction of the costs.
Muvunzi et al. [12] proposed a method for designing hot stamping tools with conformal cooling
channels. The suggested method involves the evaluation of the part to decide whether it is suitable
for AM application, the definition of conformal cooling parameters and the design of alternative
layouts. Vallas et al. [13] explored the increase of cooling capacity of tools by using the new high
thermal conductivity tool steel powders FASTCOOL-50 and HTCS-230.
In this work, a methodology for the design of CCC inside hot stamping tools is presented and the
Press Hardening of an automotive B-Pillar in 22MnB5 has been used as case study. By choosing a
commercially available tool steel powder with high thermal conductivity, an optimization of the
distance between the cooling channels (p) and distance between the tool surface and the cooling
channel centre (d) has been performed. The design and the optimization phases for the investigated
case involves, initially, the thermal analysis as a function of the geometric channels parameters on a
simplified tool geometry with a flat surface and straight channels. Thereafter, with the aim to define
an optimal channel configuration, the thermal analysis has been carried out on a real case study (an
insert of the B-pillar with conformal cooling channels), varying the geometric channels parameters
(d, p). The thermal cycles on the tools and on the formed part, the microstructural evolution of the
formed part during the quenching phase and the presence of hot spots has been evaluated.

Material and Method

The case study shown in this work to explain a method for designing the conformal cooling
channels is the Press-Hardening of an automotive B-Pillar in 22MnB5 advanced high-strength boron
steel, known as USIBOR®1500, that is the registered trademark of the steel producer ArcelorMittal.

Fig. 1: Scheme of adopted procedure

The high strength of this material is reached thanks to the quenching phase in the water-cooled
stamping tools. Therefore, cooling channels inside hot stamping tools play an important role in the
temperature uniformity of tools, in the cooling efficiency and in the microstructural evolution in the
stamped part. In this work, a methodology to optimize the cooling system characterized by CCC is
proposed. The procedure is illustrated in Figure 1.
 Key Engineering Materials Vol. 926 647

Specifically: (i) in the first phase (Fig. 1a), using a 3D transient Finite Element (FE) thermal model
developed in Comsol Multiphysics, a preliminary investigation of tool thermal cycles, varying the
distance between the cooling channels (p) and distance between the tool surface and the cooling
channel center (d) has been carried out. For this model, a simplified tool geometry with a flat surface
and straight channels has been used. (ii) The modelling of conformal cooling channels the hot
stamping tools has been performed through a CAD modelling software. Each configuration has been
imported in the AutoForm FE code and the Press-Hardening process has been numerically simulated
(Fig. 1b). On the base of thermal cycles on surface of tool insert and in the part, an optimal solution
have been chosen, by evaluating the value of peak temperature, the tool temperature at the beginning
of the next stamping cycle and the number of cycle needed to reach the steady state condition. (iii) In
correspondence with the identified optimal solutions the temperature distribution and presence of
eventual hot spots in the tool insert have been investigated with a 3D FE thermal model developed in
Comsol Multiphysics (Fig. 1c).

Investigation of the temperature distribution using a simplified tool geometry

A transient 3D thermal model has been developed using Comsol Multiphysics FE software. The
model simulates the quenching and the cooling in air phases during several stamping cycle in a press-
hardening process. A simplified tool geometry with a flat surface and straight channels has been used
and, with the aim of reducing the number of element and the iteration time, only the lower tool and
half thickness of the blank have been modelled. Figure 2 shows a scheme of the model geometry and
the cooling channels parameters, i.e. the distance between the cooling channels (p) and the distance
between the tool surface and the cooling channel centre (d). The thermal analysis has been carried
out as a function of geometrical parameters p and d. Table 1 repots the investigated values of p and d
parameters.

Table 1: Values investigated for

geometrical parameters of cooling
channels

p (mm) d (mm)
12 9
18 15
24 21
Fig. 2: Scheme of simplified FE model s

Table 2a: Values of tool parameters Table 2b: Values of blank parameters
Tool parameters Blank parameters
Thermal conductivity (W/m⋅K) 54 Thickness (mm) 1.7
Thermal conductivity (W/m⋅K) 32
Heat capacity (J/kg⋅K) 480
Heat capacity (J/kg⋅K) 470
Density (kg/m3) 8040 Density (kg/m3) 7800
Young’s modulus (GPa) 210 Young’s modulus (GPa) 210
Poisson ratio 0.3 Poisson ratio 0.3

For the thermal analysis the initial temperature of the tool and the Heat Transfer Coefficient (HTC)
have been set respectively equal to 20 °C and 3000 W/(m2 K). The HTC parameter has been assumed
to be constant. For the choice of the value of the HTC between tool surface and blank, the work of
Lechler et al. [17] has been considered as reference. Moreover, a Reynolds number equal to 4000 has
been imposed, in order to obtain a turbulent water flow. The initial blank temperature at the beginning
648 Achievements and Trends in Material Forming

of the quenching phase and the quenching time have been set respectively equal to 650 °C and 18 s.
The cooling in air time have been set equal to 14s. Tool and blank parameters are specified
respectively in Table 2a and in Table 2b. The properties of the tools shown in Table 2a are
characteristics of commercially available powders (HTCS1) with high thermal conductivity that are
used to manufacture tools with the L-PBF (Laser Powder Bed Fusion) technique.
Having assumed the manufacturing of cooling channel by means a L-PBF technique, the diameter
of the channels has been set at 6 mm. Beyond this value, in fact, it is necessary to use internal supports
that cannot be removed after manufacturing the tool. The presence of such supports is not
recommended as it can adversely affect the flow conditions inside the channels [18].

Investigation of the temperature distribution of the tool surface

The press-hardening process of a B-Pillar has been modelled in AutoForm FE software, using the
Conformal Cooling Channels corresponding to the p and d parameters reported in Table 1. Each of
the nine thermo-mechanical simulations has been performed to analyse twenty consecutive hot
stamping cycles. Figure 3 shows the tools modelled in AutoForm (Fig. 3a) and a detail of the insert
with conformal cooling channels (Fig. 3b).

Fig.3: Tools of investigated B-Pillar (a) and detail of tool insert (b)

Table 3: Process parameter for hot stamping FE simulation

in AutoForm environment 4
HTC, mW/(mm2K)

Process parameters Values 3

Blank heating temperature (°C) 950
2
Transport time (s) 5
1
Positioning and drawing time (s) 7
0
Quenching time (s) 18 0 5 10 15 20 25 30 35 40
Cooling water temperature (°C) 20 pressure, MPa
Fig. 4: Pressure dependent HTC
Quenching force (ton) 400

The process parameters adopted for the numerical simulations of the hot stamping process in the
AutoForm environment are shown in Table 3. The model simulates the transport phase of the sheet
from the furnace into the press and the cooling in air phase of the component as well as the drawing
and quenching phases. Some blank and tools parameters are reported in Tables 2a and 2b. The HTC
coefficient has been defined as a function of gap and contact pressure between sheet and tool. The
gap change the contact conditions and it can occur due to the sheet thinning. Figure 4 shows the
influence of contact pressure on HTC coefficient. Scale factor for the variation of HTC coefficient as
a function of the contact pressure and the value of the gap for which the HTC is halved have been
chosen referring to the work of Lechler et al. [17].
 Key Engineering Materials Vol. 926 649

Investigation of the temperature distribution in the tool insert

With the aim to analyse the temperature distribution in the tool insert highlighted in Figure 3, a
transient 3-D thermal model has been developed using Comsol Multiphysics FE software. The model
simulates the quenching and the cooling in air phases during several stamping cycle in a press-
hardening process. The formed part and tool parameters are the same as entered in Tables 3a and 3b,
while the process parameters are the same as described in section 1.1.

(a) (b) (c)

Fig. 4: Geometric model of the conformal cooling channels(a), the die and the punch (b) and the blank(c)
Figure 4 shows the geometric model of the conformal cooling channels (Fig. 4a), the die and the
punch (Fig. 4b) and the blank (Fig. 4c). An unstructured tetrahedral mesh has been chosen for the
numerical simulations.

Results and Discussion

Thermal analysis on simplified FE-model
The simplified FE-model has been used to investigate the effect of cooling channel parameters (p,
d) on tool temperature distribution. The range shown in Table 1 has been selected on the base of
surface temperature uniformity that decreases with the increase of the distance between channels (p)
and the reduction of distance between the cooling channel centres (d). The result analysis focused on
the comparison of thermal cycles on the tool surface in the central point. For all investigated channel
configurations, the tool peak temperature, the tool temperature at the beginning of the next stamping
cycle and the number of cycles needed to reach the steady state condition have been evaluated.

d9/p12 d21/p24
120
Tool temperature, °C

95

70

45

20
0 50 100 150 200 250 300 350
Time, s
Fig. 5: Thermal cycles on tool surface with cooling Fig.6: Metamodel for the evaluation of the tool
channels in two geometric configuration temperature at the end of the stamping cycle

Figure 5 shows the extreme thermal cycles, obtained using the following cooling channels
configurations: (i) Minimum values of d and p parameters (d = 9 mm and p = 12 mm). (ii) Maximum
values of d and p parameters (d = 21 mm and p = 24 mm). The other cooling channels configurations
show thermal cycles between curves drawn in Figure 5. Results show that minimum value of tool
peak temperature and tool temperature at the end of the hot stamping cycle is obtained with the lowest
650 Achievements and Trends in Material Forming

value of d and p parameter investigated (d = 9 mm and p = 12 mm). Moreover, tool peak temperature
varies in the range 100 °C - 118 °C, tool temperature at the end of the hot stamping cycle varies in
the range 27 °C - 46 °C, while stationnary conditions are reached after about 10 cycles. Using Kriging
technique, the tool temperature at the end of the stamping cycle in the steady state condition has been
modelled as a function of d and p parameters. The obtained metamodel (Fig. 6), highlights the effect
that an increase of both d and p parameters have on the increasing of the tool temperature at the end
of the stamping cycle.

Thermal analysis on FE-model with B-Pillar insert in AutoForm environment

Press-hardening process of a B-Pillar has been simulated with AutoForm software using CCC with
the cooling channel parameters reported in Table 1. In post-processing phase, temperatures on the
central points of tools surfaces (punch and die) have been analysed observing twenty hot stamping
cycles, for all the CCC configurations.
Figure 7 shows the punch thermal cycles corresponding to the extreme configurations. These
results confirm that an increase in d and/or p parameter leads to an increase both of the tool peak
temperature and of tool temperature at the end of the stamping cycle. To better evaluate after how
many hot stamping cycles the steady state condition is reached, the punch temperature difference
between two consecutive hot stamping cycles at the end of quenching phase has been calculated (Fig.
8). It is possible to state that in the configuration with the cooling channels closest to the tool surface
and closest to each other, the temperature stabilizes already starting from the sixth cycle (temperature
difference equal to zero). For the configuration with cooling channels at maximum distance from the
punch surface and at maximum centre distance, the temperature difference is below 1 °C starting
from the seventh cycle, but the temperature difference decreases to zero in the twelfth cycle.
Therefore, the twelfth cycle can be considered as the steady state condition for all the geometric
configurations of the CCC.

d9/p12 d21/p24 d9/p12 d21/p24

180 16
Temperature difference, °C
Punch temperature, °C

140 12

100 8

4
60

0
20 0 2 4 6 8 10 12 14 16 18 20
0 80 160 240 320 400 480 560 640
Time, s Number of cycles

Fig. 7: Thermal cycles on punch surface with cooling channels in Fig.8: Punch temperature difference between
two configuration two consecutive hot stamping cycles

Figure 9 shows the steady-state thermal cycles in the two extreme conditions and the respective
temperature distributions in the tool. The results show that as the geometric parameters of the cooling
channels vary, the peak temperature of the tool varies in the range 126 °C - 154 °C, while the tool
temperature at the end of the hot stamping cycle varies in the range 42 °C - 82 °C. The lower values
of these ranges are obtained using d = 9 mm and p = 12 mm and for this configuration it is possible
to reach the steady state condition first, already from the sixth stamping cycle. In the steady state
condition, all the CCC configurations investigated assure in the quenching phase cooling rate in the
formed part higher than 50 K/s; therefore the complete martensitic transformation is guaranteed.
Taking as reference the less severe channels configuration (d = 21 mm and p =24 mm), in the
Figure 10 is shown the time evolution of the martensitic transformation on the blank during the
quenching phase. This result highlights that just three seconds from the start of the quenching phase,
 Key Engineering Materials Vol. 926 651

greatest part of the formed part has a completely martensitic microstructure, while after 14 s, the
formed part is fully martensitic.
d9/p12 d21/p24
Punch temperature, °C 180
150
120 (b)
90
60
30
(a)
0
610 616 622 628 634 640
Time, s

Fig. 9: Thermal cycles in the steady state condition for the two most extreme condition
and the respective temperature distribution on the punch

Fig.10: Martensite history during quenching phase (d = 21 mm, p = 24 mm)

Fig. 11: Metamodel related to the quenching time that guarantees the complete
martensitic transformation as p and d vary
Therefore it can be considered that the additive manufacturing approach that ensure conformal
cooling channels production and the use of materials with high thermal conductivity allows the
complete martensitic transformation of the component in approximately 14 s during quenching phase,
less than the 18 s imposed. By tracking the temporal evolution of the martensitic transformation
during the quenching phase for all the conformal cooling channels geometric configurations, the
metamodel in Figure 11 can be obtained. It can be observed that as the parameters p and d are reduced,
the quenching time necessary to guarantee the complete martensitic transformation is reduced. This
suggests as optimal channel configuration, that obtained with d = 9 mm and p = 12mm.
652 Achievements and Trends in Material Forming

Thermal analysis on FE-model with B-Pillar insert in Comsol Multiphysics environment

The optimal channel configuration highlighted in section 2.2 (d = 12 mm and d = 9 mm) has been
investigated with the transient 3D FE thermal model described in section 1.3. This model allows to
evaluate the temperature distribution not only on the tool surface but also on the entire tool volume.

Fig. 12: Thermal cycles recorded during 20 hot stamping cycles at 30 mm from the punch
and die surfaces and on the punch and die surfaces

Fig.13a:Die temperature Fig.13b: Die temperature Fig.13c: Temperature distribution in the

distribution in the steady condition distribution in the steady condition cross sections of the die at the end of the
at the time corresponding to the at the time corresponding to the stamping cycle in the steady state
peak temperature end of the hot stamping cycle condition.

Figure 12 shows the thermal cycles in the punch and in the die recorded both at 30 mm from the
tool surface centre (pointPunch, pointDie) and in the point of the tool surface where are observed
maximum temperatures (maxPunch, maxDie), during twenty hot stamping cycles. In addition, Figure
12 also shows the details of the thermal cycles at steady state. It can be seen that the peak temperatures
recorded at 30 mm from the tool surface are about 33% lower than those obtained on the punch and
die surfaces. Moreover, it is possible to observe that, while on the tool surface the thermal cycles of
the die and the punch coincide, at 30 mm from the tool surface temperatures are lower in the die
respect to those recorded in the punch because they depend from the tool shape. Finally, it can be
highlighted that the steady state condition is reached starting from the tenth stamping cycle.
In Figure 13a and in Figure 13b, the die temperature distribution in the steady-state is shown at the
time corresponding to the peak temperature and at the time corresponding to the end of the hot
stamping cycle, respectively. On the other hand, Figure 13c shows the temperature distribution in the
cross sections of the die at the end of the stamping cycle in the steady state condition. From Figure
13a it can be seen that the peak temperature of the die ranging between 100 °C and 160 °C on the
surface, while in the remaining part of the die, not in direct contact with the hot blank, the temperature
is about 40 °C. From Figure 13b, on the other hand, it is observed that the heat is distributed by
 Key Engineering Materials Vol. 926 653

conduction in the entire volume of the die. In particular, analyzing the temperature distribution in the
cross sections of the die (Fig. 13c), it is observed that near the cooling channels the temperature is
slightly higher than 40 °C while moving away from the cooling channels the maximum temperature
recorded is 50 °C. From these figures, it emerges that although there are hot spots, in these points,
compared to the remaining areas of the tool, the temperature increase of about 20 °C. This temperature
increase is negligible, therefore the geometric solution for conformal cooling channels with p = 9 mm
and d = 12 mm is actually an optimal solution.

Conclusion
In this work, a methodology has been presented for the optimization of the cooling system of the
tools adopted for the Press-Hardening process to manufacture a B-Pillar in 22MnB5. The cooling
system must be effective to ensure the complete martensitic transformation of the component, i.e.
high mechanical resistance, to reach a steady state condition in a few cycles to give the stamped
components constant microstructural characteristics for each stamping cycle and, finally, to avoid
increasing operating temperatures to prolong the lifespan of the tools.
The optimization has been carried out by varying the parameters p and d, i.e., the distance between
the cooling channels and the distance between the cooling channels centre and the tool surface.
With this aim, to reduce computational costs, a simplified model has been first developed with a
tool flat surface and straight channels. The model made it possible to identify channel configurations
of possible interest, the steady state condition (evaluated in about 10 stamping cycles), and the
channel configuration with lower peak temperatures and temperatures at the end of the stamping cycle
(d =12 mm and p =9 mm).
The model developed in AutoForm FE software was used to simulate several stamping cycles in
the press-hardening process of a B-Pillar. Thermal results on the tool surface agree with those of the
simplified model, allowing a more precise definition of: (i) the steady state condition (6 - 12 cycles
switching from the most severe to the least severe channel configuration). (ii) The tool peak
temperatures in the steady state condition, which vary between 126 °C and 154 °C. (iii) The tools
temperatures at the end of the hot stamping cycle, which vary between 42 °C and 82 °C. The
microstructure evaluation in the formed part showed a decrease of the quenching time needed for the
complete martensitic transformation, passing from the less severe to the more severe channel
configuration. The maximum quenching time simulated (14 s) is in any case less than that imposed
in the simulation of the press-hardening process (18s). The configuration of the channel with the
minimum hardening time (12), obtained with d = 9 mm and p = 12 mm, can be considered optimal
because it reduces the cycle time. The analysis of the temperature distribution in the punch and die
inserts with the optimal channel configuration, made using the transient 3D model developed with
the Comsol Multiphysics software, did not highlight any criticality caused by the presence of hot spot.

Acknowledgments
The authors are grateful to thank MIUR (PICO&PRO project) for funding this research, AutoForm
and Fiat Research Centre (CRF) for the technical support.

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