DMI DIE PLATING

DMI (UK)
West Chirton Ind. Est.
Gloucester Road
North Shields
Tyne & Wear
NE29 8RQ
England
Tel: 0(191) 2575577
Fax: 0(191) 2581525
e-mail: sales@dmiuk.co.uk
web: www.dmiuk.co.uk
 CHROMIUM PLATING OF PRESS TOOLS BY THE DMI PROCESS

DMI is a surface engineering company with it's headquarters and main UK factory at North Shields, Tyne and Wear. The company also
has factories, joint venture companies and associate companies in the Netherlands, Japan, the USA, Canada, Australia and the Peoples
Republic of China. Distribution points, sales offices and agents are located world-wide.

DMI are involved in the surface treatment of new and the refurbishment of worn components for all types of industry. This involves
surface welding and machining and electroplating and grinding operations. The company specialises in the protection and refurbishment
of components for large 2 stroke marine engines. Chrome plating is used extensively in the protection of critical components against
corrosion, wear and abrasion and, as a result, DMI has established very large facilities around the world.

Chrome plating of dies has been used extensively by the Japanese car industry for many years to provide dramatic improvements in
quality, efficiency and production costs. An efficient and reliable service has been available in Europe since 1989 and was a spin off from
Europe's first Japanese transplant factory, Nissan Motors UK based in Washington, Tyne and Wear.

Nissan approached DMI in 1988 with a view to DMI becoming their Chrome Plater.
The reliable chrome plating of dies is extremely difficult due to their large size and weight, complex shape and mixture of different
surfaces including cast iron, inserts, welds, etc. to be plated simultaneously.
Having reviewed the previous attempts to chrome plate dies in Europe, it was clear to DMI that a professional approach was required to
provide the necessary level of service.
DMI were introduced to Nissan's Japanese chrome plater who had spent 17 years refining the process. A technology transfer deal was
quickly agreed.
Early attempts to chrome plate dies in Europe were carried out by plating companies using existing facilities and fitting in with other
work. This had proved unsuccessful. DMI therefore built a dedicated die plating facility.

Demand for the process grew quickly throughout Europe and, as a result, facilities were opened in Barcelona in early 1992 and at DMI's
Dutch factory in late 1992. DMI opened facilities in Australia and the United States in 1996, South Korea and Mexico in 2002 and Brazil
in 2003. Further expansion is planned.
 WHY CHROMIUM PLATING ?

There are many problems associated with the production of body panels.

Requirements for improved performance, greater fuel efficiency, improved

corrosion resistance and improved safety, together with changing environmental
legislation make demands on the automotive designer.

The use of thinner panel sections and specialist coatings together with changing
paint specifications and improved quality demands have resulted in greater
problems in the press operation.

As new materials such as laser textured steels and aluminiums and new coatings
such as nickel zinc are adopted, these problems are likely to increase.

These problems, and the benefits which chromium plating can give, can be
summarised as follows:
 WEAR

All tools wear.

The traditional method of repair is to weld the area of wear and re-profile the tool by machining, hand
grinding, dressing etc. This is time consuming, expensive and very inefficient.
The success of the repair is very dependant on the skills and ability of the operator.
Many panel materials such as aluminium, and coatings such as nickel/zinc, are particularly abrasive.
This can lead to excessive wear of the tool which then requires maintenance and repair on an all too regular basis.
Repairing of tools by this method will also involve time consuming 'try-outs' to assess the success of the repair prior
to the tool being used in production.
Modern production requires smaller press runs with less time between runs.
The time taken to effect repairs and prove them by try outs can result in serious 'bottlenecks' in the production schedule.

The DMI process deposits a thin layer of hard chromium (nominally 25 - 50µm thick and 1100HV - 73HRC) over
the working surface of the tool. (Fig. 1).
The chromium layer, being very much harder than the base material, resists wear far better. (Fig. 2).

WEAR INDICATOR
The chromium layer can be used to reduce the amount of wear and as a wear indicator.
When the chrome layer eventually wears through in a critical area and before excessive wear of the base material
occurs, DMI are able to remove the existing chrome layer and re-chrome the tool without effecting the base material
profile, structure or condition. This process can be repeated as often as required during the life of the tool.

No re-working of the base material is necessary and 'try-outs' can be substantially reduced or eliminated.
Fig. 1 - SECTION OF FC25 CAST IRON WITH CHROMIUM LAYER
 Fig. 2 - HARDNESS COMPARISONS

1200

1000

800

HV
600

400

200

0
CAST IRON CAST IRON STEEL Heat STEEL STEEL CHROMIUM
Heat Treated Case Nitrided
Treated Hardened
 FORMABILITY

Many problems are encountered as a result of poor formability, that is, the way the panel
material, coating and tool surface re-act during the drawing process.

Pimpling, scoring, rippling, splitting, etc. can result in high panel re-work and scrap levels
and excessive tool wear.

Additional lubrication is often required in order to achieve acceptable panel quality.

This can lead to serious handling difficulties.
Weld assembly problems may occur.
Additional operations to both apply and remove the lubricant are required.
The oil itself and the solvents used to remove it, can result in serious environmental and
disposal problems.

The polished chromium layer has a very low coefficient of friction and works well with
minimum lubrication. (Fig. 3).
This results in very good flow characteristics without the need for lubrication.
Additional lubrication can be substantially reduced and, in the majority of cases, eliminated.
Blank holder pressures may be increased to reduce rippling of the panel across the blank
holder faces.
 Fig. 3 - FRICTION CHARACTERISTICS
(Information supplied by British Steel Technical, Welsh Laboratories Ref. EC5C Report)

B / H S H IF T k N M A T E R IA L - Z IN T E C
60

50

40

30

20

10

0
TiN + OIL

CAST IRON

CAST IRON +
TiN DRY
D2 + OIL

P. N. + OIL

PLATED + OIL
D2 DRY

P. N. DRY

PLATED DRY
CHROME

CHROME
DRY

OIL
Most tool materials require lubrication to work effectively. All, with the exception of chromium, perform poorly
with no lubrication or where lubrication breaks down locally. This results in scoring, splitting, tool surface damage,
and reworking and rejection of panels.

The polished chromium layer has a low coefficient of friction and works equally as well with minimum or no
lubrication. This results in very good flow characteristics without the need for lubrication.
Lubrication can be substantially reduced and, in the majority of cases, eliminated.
 FORMABILITY

Pimpling, scoring, rippling, splitting etc. can be greatly reduced or eliminated,

thus greatly reducing or eliminating re-work and scrap levels. (Figs. 4 and 5).

Many variables affect the drawing process. Tool condition, material and coating
specifications and tolerances, press set-up etc. all have an affect.

The chromium plating of the tool produces a consistent tool thus eliminating
one of the main variables affecting the process.
 Fig. 4 - REWORK RATE
(Information supplied by SAAB and Rover)

%
5 0 .0 0

4 5 .0 0 BEFORE CHROM E

4 0 .0 0 A F TE R C H R O M E

3 5 .0 0

3 0 .0 0

2 5 .0 0

2 0 .0 0

1 5 .0 0

1 0 .0 0

5 .0 0

0 .0 0
R E A R S IL L REAR END FR O NT FRO NT S ID E REAR FR O NT FR O NT REAR HO O D AVERAG E
CD PANEL CS FENDER STRUCT. PA NE L DO OR DO O R DO OR DO O R O UTER
CS INNE R O UTER R H O UTER LH O UTER R H O UTER LH O UTER R H
U P P E R L /R CS

Blank holder pressures may be increased to reduce rippling of the panel across the blank holder faces.

Pimpling, scoring, rippling, splitting etc. can be greatly reduced or eliminated, thus greatly reducing or eliminating
re-work rates.

The results indicated above show a halving of average re-work.

 Fig. 5 - SCRAP RATE
(Information supplied by SAAB and Rover)

%
3 0 .0 0

BEFORE CHROM E
2 5 .0 0
A FTE R C H R O M E

2 0 .0 0

1 5 .0 0

1 0 .0 0

5 .0 0

0 .0 0
REAR R E A R S IL L EX TE NS. RO OF S UNR O O F S UNR O O F S ID E S ID E FRO NT FR O NT AVERAG E
Q UA R TE R CS S ID E PANEL CS PANEL C S PANEL CS, P ANE L PA NE L DO O R DO O R
O UTER PA NEL O P 40 O UTER LH O UTER R H O UTER R H O UTER LH
PANEL O UT E R L /R CD CD

Chromium has very low friction, anti-stick and hardness characteristics.

This unique combination of characteristics results in better formability and significant reductions in production
scrap rates.

The results indicated above show an average reduction down from 8.5% to 1.5%.
 FORMABILITY

The stable condition of the tool allows minimum maintenance of the tool
between press runs.

Press speed may be increased due to the improved formability. (Fig. 6).
 Fig. 6 - PRESS SPEED
(Information supplied by SAAB and Vauxhall Motors)

PPM
7 .0 0
BEFORE CHROM E
6 .0 0
A F TE R C H R O M E

5 .0 0

4 .0 0

3 .0 0

2 .0 0

1 .0 0

0 .0 0
REAR STR UC T. S ID E EX TE NS . W /HO US E FRO NT REAR S ID E S ID E S ID E AVERAG E
Q UA R TER PANEL PANEL S ID E O UT E R L /R S TR UC T. FLO O R PA NEL PANEL PANEL
O UTER INN E R INN E R PA NE L CS INNE R O UTER RH O UTER LH O UTER R H
PA NEL UP PER UP P E R L /R O U T E R L /R U P P E R L /R CS CD CD

The unique combination of surface characteristics of chromium result in more consistent production by eliminating
or reducing variables in the production process.

The more consistent performance of the tools allows for increased press / production speed.
 PANEL QUALITY

The introduction of long corrosion warranties in recent years has resulted in the increased use of electro-zinc
and hot dip galvanised materials.

These materials introduced a new range of operational and quality problems to the press operation.

'Pimpling' problems increased dramatically as particles of zinc bonded to the punch surface. These particles quickly
built up until panel quality was unacceptable at which point the press would be stopped to allow the removal of the
zinc particles. Also the batch of panels would require extensive re-work to remove the pimples.

Japanese manufacturers operating expensive high speed tri-axis transfer presses found this unacceptable and it was
found that the introduction of a highly finished chrome layer on the surfaces of the punch resisted the build up of
particles.
After chrome plating the zinc particles were more likely to stick to the panel than the punch surface and be removed,
thus preventing the build up of particles on the surface of the punch.

Similarly, the open grain structure of cast iron encourages the adhesion and build up of zinc particles on blank holder
faces which results in scored panels and scored and worn blank holder faces.
The introduction of a highly finished chrome layer resists the adhesion and build up of zinc and thus reduces scoring
on panels and eliminates blank holder surface damage.

Subsequent re-work and scrap levels could be greatly reduced. (Figs. 4 and 5).
 Fig. 4 - REWORK RATE
(Information supplied by SAAB and Rover)

%
5 0 .0 0

4 5 .0 0 BEFORE CHROM E

4 0 .0 0 A F TE R C H R O M E

3 5 .0 0

3 0 .0 0

2 5 .0 0

2 0 .0 0

1 5 .0 0

1 0 .0 0

5 .0 0

0 .0 0
R E A R S IL L REAR END FR O NT FRO NT S ID E REAR FR O NT FR O NT REAR HO O D AVERAG E
CD PANEL CS FENDER STRUCT. PA NE L DO OR DO O R DO OR DO O R O UTER
CS INNE R O UTER R H O UTER LH O UTER R H O UTER LH O UTER R H
U P P E R L /R CS

Blank holder pressures may be increased to reduce rippling of the panel across the blank holder faces.

Pimpling, scoring, rippling, splitting etc. can be greatly reduced or eliminated, thus greatly reducing or eliminating
re-work rates.

The results indicated above show a halving of average re-work.

 Fig. 5 - SCRAP RATE
(Information supplied by SAAB and Rover)

%
3 0 .0 0

BEFORE CHROM E
2 5 .0 0
A FTE R C H R O M E

2 0 .0 0

1 5 .0 0

1 0 .0 0

5 .0 0

0 .0 0
REAR R E A R S IL L EX TE NS. RO OF S UNR O O F S UNR O O F S ID E S ID E FRO NT FR O NT AVERAG E
Q UA R TE R CS S ID E PANEL CS PANEL C S PANEL CS, P ANE L PA NE L DO O R DO O R
O UTER PA NEL O P 40 O UTER LH O UTER R H O UTER R H O UTER LH
PANEL O UT E R L /R CD CD

Chromium has very low friction, anti-stick and hardness characteristics.

This unique combination of characteristics results in better formability and significant reductions in production
scrap rates.

The results indicated above show an average reduction down from 8.5% to 1.5%.
 PANEL QUALITY

Particles which did adhere to the tool surfaces could be removed easily by
wiping with a cloth rather than by the lengthy process of stoning.
It was found that press down time could be reduced from levels as high as 25%
to zero by the use of chrome. (Figs. 7 and 8).

The low friction characteristics of the chrome layer allow for greater blank holder
pressures to be used resulting in reduced rippling, reduced blank holder face wear
and reduced re-work.
 Fig. 7 - PRESS DOWN TIME
(Information supplied by SAAB and Rover)

%
3 0 .0 0

BEFORE CHROM E
2 5 .0 0
A F TE R C H R O M E

2 0 .0 0

1 5 .0 0

1 0 .0 0

5 .0 0

0 .0 0
R EAR E ND STRUCT. R EA R END S UP PO R T FR O NT S ID E S ID E FR O NT FRO NT HO O D AVERAG E
PANEL PA NE L P ANE L C S P R O F IL E STRUCT. PA NEL P ANE L DO OR DO O R O UTER
IN N E R IN N E R O UTER RH O UTER R H O UTER R H O UTER LH
UPPER UP P E R L /R CS CD

The unique combination of surface characteristics of chromium result in more consistent production by eliminating
or reducing variables in the production process.

The more consistent performance of the tools allows for increased press / production speed.
 Fig. 8 - PRESS DOWN TIME
(Information supplied by SEAT)

HOURS
100
BEFORE CHROM E
90 A F TE R C H R O M E

80

70

60

50

40

30

20

10

0
Roof B P illa r F ro nt D o o r Inne r F ro nt D o o r Inne r F ro nt F e nd e r Inne r

The unique combination of surface characteristics of chromium result in more consistent production by eliminating
or reducing variables in the production process.

The more consistent performance of the tools allows for increased press / production speed.
 OTHER BENEFITS

TOOLING COSTS

To combat wear and improve formability, tools are often manufactured from highly alloyed cast irons. These can be both difficult to
cast with a higher risk of inclusions, porosity, etc. and difficult to machine and are therefore very expensive in relation to simpler grades
of cast iron and have a longer 'lead time'.

When tools are manufactured with the intention of having them chrome plated, they can be manufactured from cheaper, more easily
machined cast irons.
The majority of tools manufactured with the intention of having them chrome plated are manufactured from standard, flake grey cast
irons such as FC25 or FC30.

This can substantially reduce the costs of new tooling.

TIME

The DMI process is quick, normally 3 - 4 days or even quicker, and can fit in with production schedules.

OTHER BENEFITS

The above benefits can apply to a wide range of pressed materials including mild steels, coated steels, aluminium, stainless steel, etc.

The DMI process can be applied equally as well to old and new tools in a wide range of materials including all grades of cast irons, with
or without high nickel weld repairs and inserts, tool steels, flame hardened steels, laser hardened steels, boiler plate, etc.
 SUMMARY

Chrome plating can be used to reduce wear and as a wear indicator to eliminate time consuming and expensive repairs
and try outs.

Chrome plating allows for lower grades of cast irons to be used in the manufacture of tooling.

Chrome plating allows for minimum lubrication, eliminating cost, handling, environmental and disposal problems.

Chrome plating can result in increased press speeds due to improved formability.

Chrome plating stabilises tool condition and thus eliminates a major variable in the press operation.

Chrome plating resists the adhesion of particles and thus greatly reduces or eliminates pimpling, re-work, scrap and press down time.

The DMI process is quick and reliable.

The benefits can be applied to a wide range of panel materials and coatings.

The process can be applied to a wide range of base materials.

The process can be applied to old and new tools, with or without weld repairs, inserts etc.

Having processed over 10,000 dies in Europe, DMI have the experience to provide an efficient, quick and reliable service.
 DMI (UK)
DMI
AUTOMOTIVE DMI (EUROPE)
TECNOCROM SEO
KWANG
KOKA CHROME
DMIA
MEXICO

CASCADURA
BRAZIL

HARDCHROME

DMI continue to develop the process to meet changing demands