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Sheet Metal Hydroforming, Guidelines by wys12714


Sheet Metal Hydroforming, Guidelines document sample

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 Center for Precision Forming

Taylan Altan, Director (email:

                   A short Review
                      July, 2011
                    Introduction                       CPF

• The Ohio State University (OSU) and have established the
  Industry/University Cooperative Research Center (I/UCRC) on
  Precision Forming (CPF) focusing on research needs of metal
  forming industry.

• Funding is provided by National Science Foundation (NSF) and
  member companies.

• CPF ( benefits from research conducted at
  Engineering Research Center for Net Shape Manufacturing
  (ERC/NSM –

                        Objectives                                 CPF

• Improve existing metal forming processes/products and develop new
  innovative processes, tooling and equipment.

• Conduct projects in close collaboration with industry and transfer the
  results to the member companies.

• Train and educate engineers in the fundamentals and practice of metal
  forming science and technology.

         Current Members                         CPF
• Aida- America Corp.
• Boeing
• ESI North America
• General Motors Corp.
• Interlaken Technology Corp.
• POSCO (Korea)
• IM Steel
• Scientific Forming Technologies (SFTC) Corp.
• IMRA America
• Metalsa
• Thixomat
• Tyco
•Cincinatti, Inc                                  4
                     Current Projects                               CPF
CPF 1.1: Elevated temperature stamping and hydroforming of Al, Mg and
Stainless Steel

Develop guidelines for elevated temperature sheet forming (process optimization,
lubricant evaluation and Finite Element Modeling)

       Warm deep drawing (in cooperation with AIDA Engineering, Ltd.)
                     Current Projects                                  CPF
CPF 1.4: Investigation of springback in forming Advanced/High
Strength Steel (A/HSS)
   Determine the variation of Young’s Modulus with deformation /strain
   Predict and reduce springback in stamping A/HSS

                                     Planned experiments (Tool concept)
                                     1. Straight flanging
                                     2. Stretch flanging
                                     3. Shrink flanging
                                     4. Straight hat shape drawing and stretching
                                     5. Curved hat shape drawing and stretching

                    Current Projects                            CPF
CPF- 2.1: Determination of room temperature properties of Al and steel
sheet materials under biaxial conditions
Develop a standardized tool design and procedure to determine flow stress,
anisotropy and formability under biaxial deformation

                                                    Sheet bulge test
                                            (Viscous Pressure Forming –VPF)

                      Current Projects                                CPF
CPF- 2.2: Determination of flow stress of Al and Mg sheet materials at
elevated temperatures
Determine flow stress of sheet materials at elevated temperatures for the warm
forming process.


                                               Modified Limiting Dome Height
                                                        (MLDH) Test
     Inverse Analysis Technique                      Formed sample
                                                  (OD = 14in, t0 = 0.034in)
                      Current Projects                                          CPF
CPF- 2.3: Investigation of tribological conditions in forming uncoated
and galvanized Advanced/Ultra High Strength Steels (A/UHSS)
Determine the effect of process parameters (interface temperature, pressure and
relative sliding speed) on galling / reduce galling
                                                          Micrograph of galled surface

                                       Tool surface



  Twist compression Test (TCT)                                           Galling
     (in cooperation with IRMCO)       • Testing materials: DP 600 Bare with Lub A   9
                                       • Testing conditions: P = 170 MPa & N= 8.9 RPM
                    Current Projects                                    CPF
CPF - 4.1: Multi Point Control (MPC) die cushion and blank holder
technology in stamping
Develop an automated system to optimize the Blank Holder Force for robust


                                Blank holder /

                                 Individual hydraulic
                                  cylinders for each    Location of cushion pins/
                                     cushion pin           cylinders in the die
    (Source: Müller Weingarten)                                        (continue)

             Proposed system for robust stamping using MPC
                          Current Projects                                           CPF
CPF - 4.1: Multi Point Control (MPC) die cushion and blank holder
technology in stamping (continue)

Parts formed with OSU software by USCAR (try-out reduced from 3 days to 3 hours)

   Al 6111-t4 (t = 1 mm)            BH210 (t = 0.81 mm)              DP500 (t = 0.78 mm)

Sample parts [GM lift gate inner panel] with different materials and sheet thickness was formed in
                            the same die by simply adjusting the BHF.

                    Current Projects                                CPF
 CPF- 4.2: Applications of Tube Hydroforming (THF) Technologies
Utilize past R&D experience at OSU to assist interested companies in
introducing and/or improving the hydroforming technology

   A.                                C.

   B.                                D.

                                                            [Leitloff , 1997 ]
             General concept of Tube Hydroforming Process
                  (Hydroforming of the T-shape part)                     12
      Center for Precision Forming CPF

New tasks under consideration

• Cold and Warm Hydroforming of Al and Mg alloys

• Simulation of Hot Stamping of Boron Steels

• Precision /Flashless Forging of automotive components (for example
  tie rods, pinion gears and bevel gears)

• Prediction and reduction of residual stresses in machining and burnishing
  (advanced FE analysis)

• Micro-stamping for electronic applications (lead frames, CD drive
  components, etc.)


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