A case study on the design of a hot stamping tool with conformal cooling channels

Additive manufacturing (AM) can be used to manufacture tool inserts with cooling channels conforming to the shape of the part to be produced. This results in shorter cycle times and improved quality. In the hot stamping industry, there is need to reduce cycle time and improve quality. The process differs from injection moulding since it involves larger tool inserts, high temperature and forces. In hot stamping tools, the cooling channels are in the form of straight drilled channels. These channels do not have the capacity to cool complex shaped parts consistently due to restrictions in machining. There is need for further studies on the design of hot stamping tools with AM-based cooling channels. The aim of this paper is to propose a method for designing hot stamping tools with conformal cooling channels. The method involves firstly evaluating the part to decide whether it is suitable for AM application, determining conformal cooling parameters and developing alternative layouts. This is followed by selection of the optimum layout and obtaining the cooling system parameters.