Docstoc

Sheet Metal Hydroforming, Guidelines

Document Sample
Sheet Metal Hydroforming, Guidelines Powered By Docstoc
					                                                  CPF

 Center for Precision Forming
                 (www.cpforming.org)


Taylan Altan, Director (email: altan.1@osu.edu)

                   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 (www.cpforming.org) benefits from research conducted at
  Engineering Research Center for Net Shape Manufacturing
  (ERC/NSM – www.ercnsm.org).




                                                         2
                        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.




                                                                      3
         Current Members                         CPF
• Aida- America Corp.
• Boeing
• EWI
•Honda
• ESI North America
• General Motors Corp.
• Interlaken Technology Corp.
• POSCO (Korea)
• IM Steel
• Scientific Forming Technologies (SFTC) Corp.
• IMRA America
• Metalsa
• JCI
• Thixomat
• Tyco
•Labein
•Cincinatti, Inc                                  4
                     Current Projects                               CPF
CPF 1.1: Elevated temperature stamping and hydroforming of Al, Mg and
Stainless Steel

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




       Warm deep drawing (in cooperation with AIDA Engineering, Ltd.)
                                                                        5
                     Current Projects                                  CPF
CPF 1.4: Investigation of springback in forming Advanced/High
Strength Steel (A/HSS)
Objectives:
   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



                                                                          6
                    Current Projects                            CPF
CPF- 2.1: Determination of room temperature properties of Al and steel
sheet materials under biaxial conditions
Objective:
Develop a standardized tool design and procedure to determine flow stress,
anisotropy and formability under biaxial deformation




                                                    Sheet bulge test
                                            (Viscous Pressure Forming –VPF)




                                                                   7
                      Current Projects                                CPF
CPF- 2.2: Determination of flow stress of Al and Mg sheet materials at
elevated temperatures
Objective:
Determine flow stress of sheet materials at elevated temperatures for the warm
forming process.


                                              Hole




                                               Modified Limiting Dome Height
                                                        (MLDH) Test
     Inverse Analysis Technique                      Formed sample
                                                  (OD = 14in, t0 = 0.034in)
                                                                          8
                      Current Projects                                          CPF
CPF- 2.3: Investigation of tribological conditions in forming uncoated
and galvanized Advanced/Ultra High Strength Steels (A/UHSS)
Objective:
Determine the effect of process parameters (interface temperature, pressure and
relative sliding speed) on galling / reduce galling
                                                          Micrograph of galled surface

                                       Tool surface
                                   P
                          rm



                               A




                                   T

  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
Objective:
Develop an automated system to optimize the Blank Holder Force for robust
stamping

                                 Die


                                Blank holder /
                                   Binder




                                 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
                                                                            10
                          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.



                                                                                         11
                    Current Projects                                CPF
 CPF- 4.2: Applications of Tube Hydroforming (THF) Technologies
Objective:
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
                 (CP-Forming-www.cpforming.org)

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.)


                                                                      13

				
DOCUMENT INFO
Shared By:
Categories:
Tags:
Stats:
views:76
posted:8/23/2011
language:English
pages:13
Description: Sheet Metal Hydroforming, Guidelines document sample