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Center for Precision Forming
(www.cpforming.org) Taylan Altan, Director (email: firstname.lastname@example.org)
A short Review July, 2011
Center for Precision Forming (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).
Center for Precision Forming (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.
Center for Precision Forming (CPF)
• IMRA America • Metalsa • Tyco Center for Precision Forming (CPF) .Current Members •Boeing •Cincinnati Inc •Dienamic Tooling Systems CPF •ESI North America • EWI •Honda •Hyundai • ESI North America • Interlaken Technology Corp. • POSCO (Korea) • IM Steel • Scientific Forming Technologies (SFTC) Corp.
cpforming.R & D at The Center for Precision Forming CPF Research and Development in Sheet Metal Forming Center for Precision Forming (CPF) (formerly Engineering Research Center for Net Shape Manufacturing) www.org / www. Ohio © Copyright Center for Precision Forming (CPF). Center for Precision Forming (CPF) . All Rights Reserved.ercnsm. Columbus.org The Ohio State University June 1st 2011.
formability.5 – Evaluation of lubricants for improving stamping quality CPF 4.4 AHSS parts Control of springback and dimensional tolerances in forming CPF 2.1 – Practical use of multi-point control (MPC) die cushion technology in production of stamped parts Center for Precision Forming (CPF) 6 .3 – Investigation tribological (friction/lubrication/wear) conditions in forming uncoated and galvanized AHSS CPF 2.R&D in Sheet Metal Forming at CPF CPF CPF 1. anisotropy) of sheet materials under biaxial conditions CPF 2.1 – Determination of room temperature material properties (flow stress.Elevated temperature stamping and hydroforming (Mg. Al and alloys) CPF 1.1 .
R&D in Sheet Metal Forming at CPF CPF CPF 4.1 – Evaluation of bendability of AHSS CPF 5.3 – Blanking and shearing of sheet metal CPF 5.2 – Tube hydroforming CPF 5.6 – Applications of servo drive presses in stamping Center for Precision Forming (CPF) 7 .5 – Hot stamping of boron steels CPF 5.2 – Prediction and elimination of edge cracking of AHSS in stretch flanging CPF 5.
Elevated Temperature Stamping and Hydroforming (Mg. Al And Alloys) Manan Shah Jose L.CPF CPF 1. Gonzalez-Mendez Eren Billur Center for Precision Forming (CPF) 8 .1 .
5-50mm/sec 2.9 275 3.Warm Forming of Al.6 Velocity : 2.2 Center for Precision Forming (CPF) 9 .5 275 2. Mg.1 RT 2. Ti & SS (Cup Diameter: 40 mm) (in cooperation with AIDA) CPF AA5754-O AZ31B-O T(°C) RT 250 300 LDR T(°C) LDR 2.
Warm Forming of SS 304 (Cup Diameter: 40 mm) (in cooperation with AIDA) CPF Center for Precision Forming (CPF) 10 .
nj and mj) FE Output 40 Bulge Height (mm) Bulge Height (mm) tn t2 t1 10 20 30 40 50 60 70 Bulge height. Pexp vs Time Strain. PFE vs Time Strain. Sexp vs Time CPF Comparison One experimental output is compared with FE output for every combination (Kj. Ej) r1 Radial r2 Coordinate (mm)r5 r3 r4 Pressure. Hexp vs Time Pressure.Warm Bulge Test (up to 350C/660F) Experimental Output Bulge height. E2. …. SFE vs Time r0 Radial Coordinate (mm) K n m 11 Center for Precision Forming (CPF) . HFE vs Time 35 30 25 20 15 10 5 0 0 Every comparison results in an error function (E1.
Warm Forming FEA using PAMSTAMP 2G 2009 (in cooperation with GM and Interlaken) CPF Punch stroke= 0 mm Punch stroke= 35 mm Punch Blank Holder Punch Blank Holder Sheet Reverse Punch Fluid pressure Die Die Center for Precision Forming (CPF) 12 .
4 Center for Precision Forming for Punch Stroke= 1.4 -0.04 Thickness (mm) 3 4 5 6 7 8 1.2 -1.35 in (34.9 0 50 100 150 200 250 0.96 0.2 -0.2 0 0 -0.92 4 5 0.Warm Forming FEA and Experiments Thickness profile along the curvilinear length for sample 30 (BHF=2.94 0. Punch Stroke =1.8 -1 Part Profile Comparison-CMM and FE Curvilinear Length (mm) Experimental measurements with Error bar FE thickness profile 1 2 3 4 5 6 7 8 Part Depth (in) -1.98 0.3 mm) 13 .02 1 0.08 1.00 in) CPF 1.19 kip.06 1 Maximum Thinning location 7 2 3 6 8 1 2 1.3 mm) (CPF) CMM Data Radial Distance (in) FE profile for Punch stroke= 1.6 -0. Pot Pressure limit=2000 psi.35 in (34.
Control of Springback and Dimensional Tolerances in Forming AHSS Parts Nimet Kardes-Sever Yurdaer Demiralp Dr.4 .CPF CPF 1. Changhyok Choi Center for Precision Forming (CPF) 14 .
Springback Load-Unload Tensile Test (in cooperation with EWI) CPF Center for Precision Forming (CPF) 15 .
DP 600 thickness: 1 mm.75 mm U-flanging without stretching U-bending without stretching U-flanging with stretching U-bending with stretching S-shape forming with – without stretching Center for Precision Forming (CPF) 16 . 0.Springback in S-Die Test (FEA and Experiments) (in cooperation with EWI and IVF) CPF Material: DP 780.
Springback in S-Die Test (FEA and Experiments) (in cooperation with EWI and IVF) U-flanging test U-bending test CPF Schematic of S-shape punch U-bending sample on S-shape punch U-flanging sample on S-shape punch Center for Precision Forming (CPF) S-shape bending sample on S-shape punch 17 .
When the tool is closed it is not possible to take pictures. • For complex samples. it was assumed that the specimen geometry under load is determined by tool geometry. Therefore.CMM measurements of S-Die Test Samples Calculation of springback for S-Die Test samples: CPF • Bending angle under load was measured by camera when possible. Schematic of CMM measurements on a sample Center for Precision Forming (CPF) 18 . • Bending angle after unloading was measured by protractor and camera when possible and Coordinate Measurement Machine (CMM). sections before and after springback were compared.
Determination of Room Temperature Material Properties of Sheet Materials Under Biaxial Conditions Eren Billur Yurdaer Demiralp Nimet Kardes-Sever Ji You Yoon Center for Precision Forming (CPF) 19 .CPF CPF 2.1 .
Sheet Material Properties Viscous Pressure Bulge (VPB) Test (in cooperation with many companies) CPF Laser Test Sample Downward motion clamps the sheet Viscous Medium Pressure Transducer Stationary Punch Continued downward motion forms the bulged sheet Before Forming After Forming Center for Precision Forming (CPF) 20 .
4 0. 1000 _ Effective Stress ( ) [MPa] 800 0.Sheet Material Properties Tensile Test vs.t 0 = 1mm Bulge Test Tensile Test 0 0 0.5 200 Center for Precision Forming (CPF) 21 .1 0. VPB Test CPF Due to necking. flow stress data from tensile test is limited to low strains.3 _ Effective Strain ( ) 0.15 0. Bulge test is useful to determine flow stress curve for metal forming applications and FE simulations.2 0. Bulge test is useful to determine the quality (formability) of sheet materials.49 600 400 DP600 .
Highest formability G . Most consistent F Lower formability and inconsistent H Center for Precision Forming (CPF) 22 .Determination of Sheet Formability Using VPB Test CPF Graph shows dome height comparison for SS 304 sheet material from eight different batches/coils [10 samples per batch].
AI Type GA DP 780 Y-type U GA DP 780 Y-type V DQS-270F GA-Phosphate coated DQS-270D GA-Phosphate coated CPF St 14 St 1403 AISI 1018 AKDQ 1050 DR 120 DDS BH 210 HSS DP500 DP 590 DP 600 DP 780 TRIP 780 DP 980 Aluminum and Magnesium Alloys AA 6111 AA 5754-O X626 -T4P AZ31B AZ31B-O Stainless Steels SS 201 SS 301 SS 304 SS 409 SS 410 (AMS 5504) SS 444 LDX 2101 Center for Precision Forming (CPF) 23 .Materials Tested with VPB Test at CPF (data available to CPF members) Steels DP 780-CR DP 780-HY Bare DP 980 Y-type X Bare DP 780 T-Si type GA DP 780 T.
Investigation Tribological (Friction/Lubrication/Wear) Conditions in Forming Uncoated and Galvanized AHSS Eren Billur Ryan Patton Center for Precision Forming (CPF) 24 .CPF CPF 2.3 .
in stamping AHSS. Various die materials and coatings are evaluated by SDT and SIT.Evaluation of Die Materials/Coatings for Galling and Die Wear Using The Strip Drawing and Ironing Test (SDT/SIT) (in cooperation with HONDA ) CPF Strip Drawing Test Galling observed on a die insert Higher contact pressure accelerates the tool wear and galling. Center for Precision Forming (CPF) 25 Strip Ironing Test .
5 .Evaluation of Lubricants for Improving Stamping Quality Soumya Subramonian Nimet Kardes-Sever Yurdaer Demiralp Center for Precision Forming (CPF) 26 .CPF CPF 2.
Smaller the flange perimeter. better the lubrication condition (lower coefficient of friction) Center for Precision Forming (CPF) 27 . Higher the Blank Holder Force (BHF) that can be applied without fracture in the drawn cup. better the lubrication condition ii.(in cooperation with HONDA and several lubricant companies) Evaluation of Lubricants Using The Cup Drawing Test (CDT) CPF Performance evaluation criteria (cups drawn to same depth): i.
(in cooperation with HONDA and several lubricant companies) Flange Perimeter and Punch Force for 24 ton BHF (270D/GA) 785 780 160 150 Evaluation of Lubricants Using The Cup Drawing Test (CDT) – Results CPF Flange Perimeter (mm) 775 770 765 760 755 750 745 140 130 120 110 740 M+L21 M+L6 M + L15 M + L19 Mill oil+ Lubricant M+L23 M+L22 100 Flange Perimeter (mm) Maximum Punch Force (kN) 28 Center for Precision Forming (CPF) Maximum Punch Force (kN) .
1 . Taylan Altan Center for Precision Forming (CPF) 29 .Practical Use of Multipoint Control (MPC) Die Cushion Technology in Production of Stamped Parts Dr.CPF CPF 4.
Stuttgart) Erie binder unit (hydraulic system) with liftgate tooling inside press (Source: USCAR) Center for Precision Forming (CPF) 30 .Case studies in process simulation CPF Multi-point Control systems (MPC) Hydraulic systems IFU flexible Blank holder / Binder hydraulic control unit (Source: IFU.
Case studies in process simulation CPF Multi-point Control systems (MPC) Application of MPC die cushion technology in stamping Sample cushion pin configuration (hydraulic MPC unit) for drawing stainless steel double sink. (Source: Dieffenbacher. Germany) MPC is routinely used in deep drawing of stainless steel sinks Center for Precision Forming (CPF) 31 .
Methodology for BHF determination (Numerical optimization techniques coupled with FEA) Inputs required • Quality control parameters (wrinkling.Case studies in process simulation CPF Multi-point Control systems (MPC) Previous work at CPF in Blank Holder/Binder Force (BHF) determination • CPF in cooperation with USCAR consortium developed software to program MPC die cushion system in stamping. of cushion cylinders (n) • Tool geometry (CAD) • Material properties • Process conditions Software developed at CPF for BHF determination FEA Software (PAM-STAMP. thinning) • No. LS-DYNA) BHF at each cushion pin as function of punch stroke Center for Precision Forming (CPF) 32 .
Case studies in process simulation CPF Multi-point Control systems (MPC) Use of Multi-point Control (MPC) die-cushion systems helps to control metal flow. Each cushion pin is individually controlled by a cylinder (hydraulic/ nitrogen gas /servo control). Center for Precision Forming (CPF) 33 . Location of cushion pins/ cylinders in the die MPC can be used to accommodate variations in sheet properties & assist in forming AHSS.
AA6111-T4 Beads Initial sheet thickness : 1 mm Segmented blank holder Inner Binder [Source: USCAR/OSU] Cushion Pin Punch Outer Binder Center for Precision Forming (CPF) 34 . using FE simulation coupled with numerical optimization.Case studies in process simulation CPF Multi-point Control systems (MPC) Die FE model Estimation of BHF varying in each cushion pin & constant in stroke. Sheet Geometry : Lift gate inner Material : Aluminum alloy. developed at CPF (OSU).
sheet thickness = 1 mm) 120 Blank holder force (kN) 11 10 100 80 60 40 20 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Pin numbers 15 9 8 13 7 6 14 Pin 1 2 12 5 4 3 Pin locations and numbering Center for Precision Forming (CPF) 35 .Case studies in process simulation CPF Multi-point Control systems (MPC) BHF predicted by FE simulation in individual cushion pins for forming Aluminum alloy (A6111-T4.
Case studies in process simulation CPF Multi-point Control systems (MPC) Experimental validation of BHF prediction by FE simulation Bake Hardened steel (BH210. no tears Using a hydraulic MPC system installed in mechanical press.with three different materials/sheet thicknesses in the same die by only modifying BHF in individual cushion pins. no tears Dual Phase steel (DP600.8 mm) No wrinkles. t = 1 mm) Minor wrinkles.8 mm) No wrinkles. no tears Aluminum alloy (A6111 – T4. t = 0. Center for Precision Forming (CPF) 36 . t = 0. the auto-panel was formed successfully .
Taylan Altan Center for Precision Forming (CPF) 37 .2 .Tube Hydroforming Dr.CPF CPF 4.
Changhyok Choi Center for Precision Forming (CPF) 38 .CPF CPF 5.1 .Evaluation of Bendability of AHSS Xi Yang Nimet Kardes-Sever Yurdaer Demiralp Dr.
) CPF a) Before unloading Calculation of springback for V-die bending samples: b) After unloading • Bending angle under load was measured by camera.Prediction of Springback in V-Die Bending (in cooperation with Cincinnati Inc. • Bending angle after unloading was measured by protractor and camera. Center for Precision Forming (CPF) 39 .
) CPF FEA BEND Punch Sheet V-die Schematic of FE model in DEFORM 2D Screenshot from BEND Center for Precision Forming (CPF) 40 .Prediction of Springback with FEA and BEND in V-Die Bending (in cooperation with Cincinnati Inc.
Tool Dimensions • Punch radius • Die radius • Die opening Center for Precision Forming (CPF) 41 . Material’s properties • Strain hardening exponent (n ) • Strength coefficient (K ) • Initial yield stress (YS ) • Young’s modulus (E ) • Poisson’s ratio • Initial thickness (t0) • Sheet width (w0) • Friction coefficient (m) 2. (Channel Die or V-Die) Parameters input to the program 1.) CPF The program BEND was developed based on the analytical model to predict the springback in air-bending.Prediction of Springback With BEND in V-Die Bending (in cooperation with Cincinnati Inc.
we can obtain different stress/strain conditions at fracture.Stretch Bending Test to Evaluate Formability/Fracture CPF Die Ring Die Ring RDR Sample Sample Punch diameter: 152.4 mm RDR Lock Bead Rd Rd RP Round Sample Round Sample Round and Strip Sample Blank Holder Blank Holder Punch Punch RP before forming CL CL Lock Bead Lock Bead after forming By changing Rd and Rp. Center for Precision Forming (CPF) 42 .
2 .CPF CPF 5.Prediction and Elimination of Edge Cracking of AHSS in Stretch Flanging Soumya Subramonian Center for Precision Forming (CPF) 43 .
blanking. Center for Precision Forming (CPF) 44 . reaming.(in cooperation with US Steel and TUM) Blanking and Flanging CPF Factors Influencing Hole Expansion •Edge quality of the hole •The method used to finish the hole (e. flat bottom punch or spherical punch can be used.) •Punch/die clearance used in blanking •Positioning of burr with respect to punch •Sheet material Hole Expansion Test • To investigate the stretch-ability of the finished edges. etc.g. • A conical punch.
Blanking and Shearing of Sheet Metal Soumya Subramonian Tingting Mao Center for Precision Forming (CPF) 45 .3 .CPF CPF 5.
) Schematics of Blanking and Shearing (FEA and Experiments) CPF Blanking Shearing [www.(in cooperation with Tyco and Cincinnati Inc.com/wu/sheet-metal-shearing ] Center for Precision Forming (CPF) 46 .custompartnet.
Blanking and Shearing (FEA and Experiments) Different Zones of Blanked Edge Zr CPF Zr Zs Zs Zf Zf Zb (b) (a) Zr: rollover zone Zs: shear zone Zf: fracture/rupture zone Zb: burr Different zones of the blanked edge (a) simulations and (b) experiments Center for Precision Forming (CPF) 47 .
Blanking and Shearing Critical Parameters CPF Effects of the following parameters on the blanked edge quality and punch load/life are studied: •Punch-die clearance Load (% max load) 120 100 80 60 40 20 0 0 -20 -40 5 10 15 20 •Punch/die corner radii •Stripper pressure and design •Punch end geometry •Coefficient of friction •Punch misalignment •Snap-thru forces / reverse loading •Vibration and dynamics Snap-thru forces time Analysis of snap-thru forces during blanking through simulations Center for Precision Forming (CPF) 48 .
CPF CPF 5.Hot Stamping of Boron Steels Eren Billur Center for Precision Forming (CPF) 49 .5 .
Developed for automotive applications in the 80’s CPF .Introduction/Hot stamping . light weight parts with reduced springback Parts manufactured using hot stamping Center for Precision Forming (CPF) 50 .Fast growing and an evolving technology for manufacturing crash resistant.
Manganese Boron steel (22MnB5) has ferritic pearlitic microstructure in as received condition.These blanks are heated to austenitisation temperature(~950°C) for 5 minutes.The heated blanks are formed and quenched in the press at a cooling rate higher than 27K/sec.Quenching changes the microstructure from austenite to martensite and the final part is hardened and has an ultimate tensile strength of around 1500 MPa.Introduction/Technology Overview CPF . . Center for Precision Forming (CPF) 51 . . .
Introduction/Direct Hot Stamping CPF Direct hot stamping process Center for Precision Forming (CPF) 52 .
South Korea Tooling System Group. Center for Precision Forming (CPF) 53 .Supporting CPF/finite element simulations of hot stamping.Data base of references and information in hot stamping. Japan . Turkey . IMRA .Providing geometry and experimental data on example hot stamped components (details are proprietary). CPF POSCO. USA COSKUNOZ (die maker).Partners/Supporters National Science Foundation (NSF) .
Hoffman) Dortmund University of Technology.Graz. Mori) Technical University of Munich. Italy (Prof.International Co-operation CPF CPF maintains good relationship with several leading research institutes active in Hot Stamping technology Lulea University of Technology. Japan (Prof. Kolleck) Toyohashi University of Technology. Hannover (Prof. Germany (Prof. Sweden (Prof.Austria (Prof. Akerstrom) University of Erlangen-Nuremberg. Tekkaya) Center for Precision Forming (CPF) 54 . Germany (Prof. Germany (Prof. Bariani) Tech. Merklein) Leibniz University.Univ. Behrens) University of Padova.
PAMSTAMP. AUTOFORM for simulating the entire hot stamping process Our Strategy • Use PAMSTAMP and DEFORM 3D to predict -Temperature distribution -Thickness distribution -Metal flow -Elastic tool deflection -Cooling channel optimization • Simulate and compare results with example parts a) from literature b) provided by our partner companies Center for Precision Forming (CPF) 55 . FORGE.FE Simulation of Hot Stamping Status / Update CPF Various companies/research groups are using combination of different FE codes like LS-Dyna. Marc. MSC. ABAQUS.
Tooling for hot stamping of B-Pillar Center for Precision Forming (CPF) 56 .Case Study-1/ AUDI B-Pillar Section -Bench Mark problem-3 given in Numisheet-2008. -2D section of the part is simulated. (c) potential defects. -The objective is to predict in the CPF formed part: (a) thickness distribution. (b) hardness distribution.
Numisheet 2008 Center for Precision Forming (CPF) 57 .Case Study-1/ AUDI B-Pillar Section Input geometries for simulation CPF Die Punch Assembly Blank holder Blank Reference: Benchmark problem-3.
Case Study-1/ AUDI B-Pillar Section Top die (75 C) CPF 22 MnB5 Blank (810 C) Blank holder(75 C) Initial simulation setup Punch (75 C) Final simulation setup -A critical section of the B-Pillar is chosen for 2-dimensional simulation (DEFORM 2D /Variable mesh density) Center for Precision Forming (CPF) 58 .
-Heat transfer module available in DEFORM is used for simulation -Different combination of cooling channel configurations and examples from the literature uniform are simulated and to achieve cooling martensite Temperature distribution at the end of press stroke microstructure Center for Precision Forming (CPF) 59 . the geometry used in the case study-2 was chosen.Case study-2/ Cooling Channel Design CPF -For this case study.
Future plans CPF ---Develop a simplified and practical procedure to simulate the entire hot stamping process with reasonable accuracy using commercial codes PAMSTAMP. defects. hardness) ---Develop a simulation procedure to predict tool and part dimensions during hot pressing and correct the tool surface profile to obtain accurate part dimensions and desired hardness distribution (uniform or variable) ---Estimate residual stresses in the part after hot stamping. LS-Dyna and DEFORM (predict thinning. quenching and cooling Center for Precision Forming (CPF) 60 .
CPF CPF 5.Applications of Servo Drive Presses in Stamping Adam Groseclose Center for Precision Forming (CPF) 61 .6 .
motor torque available during the entire stroke Center for Precision Forming (CPF) 62 Servo-Drive Characteristics 1/2 CPF . anywhere in stroke • Adjustable stroke length (TDC and BDC) • Ram position/ velocity can be synchronized with automatic part transfer • In deep drawing. cycle times can be shorter than in mechanical presses • Considerable savings in energy • Dwell at BDC/ restriking/ vibrating and variable blank holder force (BHF) • Max.• Precise ram position and velocity control.
[Miyoshi. 2004] Center for Precision Forming (CPF) 63 .Crank or Link press Fixed Motion Servo-Drive Characteristics 2/2 Cycle time of mechanical press CPF Free motion press Slide Position Minimum stroke length Cycle time of Free motion press (6) Synchronize with (6) Synchronize with feeder feeder Forming length (1) Variable (1) Variable stroke stroke length length Time Standstill at BDC (5) Prevention of (5) Prevention of noise and shock noise and shock at contact or at contact or breakaway of breakaway of tools tools (2) Best speed (2) Best speed for materials for materials (3) Improve (3) Improve accuracy by accuracy by dwelling at BDC dwelling at BDC (4) Other Process (4) Other Process at BDC at BDC (Multi Process) (Multi Process) The flexibility of slide motion in servo drive (or free motion) presses.
Servo-Drive Mechanisms CPF • Low Torque/ High RPM Motors Use Ball Screws or/and Linkage Mechanisms • High Torque/ Low RPM Motors Use Existing Crank and/or Link Press Drives Center for Precision Forming (CPF) 64 .
Low RPM/High Torque Motor Drive
Power Source Capacitor Balancer tank Main gear
a) C-Frame Servo Press (Aida)
b) Stroke-Time program for warm forming of Al and Mg sheet
Center for Precision Forming (CPF)
Modern Stamping Lines Using Large Servo-Drive Presses
• BMW- Leipzig and Regensburg (Germany)/ 2500 ton servo-drive drawing press (Schuler)/ 17 SPM (2009) • HONDA- Suzuka (Japan)/ 2500 ton servo-drive drawing press (Aida)/ 18 SPM (2009) • New large press lines are planned – BMW-Schuler- 2011 – HONDA-Aida- 2011
Center for Precision Forming (CPF)
Schematic of Servo-press line (Aida/Honda) CPF 2500 ton/ 18 SPM draw press (2009)
Loading ・ Die cushions have an ・ System with optimized press ・ Press-to-Press forming requirements for each Motion: System is optimized energy regeneration for each product. product system
Center for Precision Forming (CPF)
Suzuka Plant Production Picture (Honda/Aida) CPF Center for Precision Forming (CPF) 68 .
2008].Deep Drawing 1/3 CPF Comparison between the slide motions of an 1100 mechanical and servo drive press for identical slide velocity during forming [Bloom.Applications. Center for Precision Forming (CPF) 69 .
200% increase in output) [Bloom.Deep Drawing 2/3 CPF Decrease in cycle time by reducing the stroke length and operating the servo press in “pendular” mode (progressive die stamping. 2008] Center for Precision Forming (CPF) 70 .Applications.
2008] Center for Precision Forming (CPF) 71 .Applications.Deep Drawing 3/3 CPF Decrease in cycle time as well as in impact speed using a servo press (150% increase in output) [Bloom.
Side Panel Outer Deep Drawing Case Example (Honda/Aida) CPF Center for Precision Forming (CPF) 72 .
High-speed/ High Accuracy Servo-Press (Honda/Aida) CPF Center for Precision Forming (CPF) 73 .
Servo-Hydraulic Cushion 1/2 (Courtesy-Aida) CPF Elimination of Pressure Surge in the Die Cushion Center for Precision Forming (CPF) Die Cushion Force (kN) 74 .
Servo-Hydraulic Cushion 2/2 (Courtesy-Aida) CPF Power Regeneration: Approx. 70% Power Direction Motor Torque Direction Pump Rotation Direction Linear Scale S/M S M Pressure Sensor Closed Hydraulic Circuit During Down Stroke. Cushion Pressure Generates Power Center for Precision Forming (CPF) 75 .
Optimization of Ram Velocity for Deep CPF Drawing with Servo-Drive Presses New CPF Project. Center for Precision Forming (CPF) 76 .in cooperation with the University of Darmstadt (Germany) Objective • Develop a methodology to optimize the ram velocity during deep drawing of sheet metal parts with a servo-drive press.
cost. Determination of reliable input parameters [material properties /interface friction conditions] is a key element in successful application of process simulation. Multi-point control (MPC) die -cushion systems offer high flexibility in process control.Summary CPF Process simulation using FEA is state of the art for die/process design. resulting in considerable improvement in formability. Center for Precision Forming (CPF) 77 . Advanced FE simulation + reliable input data helps to predict process parameters for forming the part and save tryout/setup time. MPC systems offer advantages in forming high strength materials. material & energy.
alloys shows improvement in formability at temperatures in the range of 250-450°C.Summary CPF Warm forming of selected Al. also in higher tonnages (2. Reliable flow stress data at elevated temperature is required as an input for accurate FE simulation of the warm forming process.and Mg. Considerable research on warm forming process and its application to production is in progress. Electric/Mechanical servo-drive presses will be increasingly used.000-4. Center for Precision Forming (CPF) 78 .000 tons). Hot stamping technology will increase rapidly (Process simulation and die design/manufacturing are major issues).
With a staff of 20 (post docs. with emphasis on forming AHSS.org Center for Precision Forming (CPF) 79 . world wide. PhD students. MS students).email@example.com) For detailed information.ercnsm.edu) or Linda Anastasi (firstname.lastname@example.org. CPF is maintaining close contacts with many other forming research labs.org and www. For questions. please contact Taylan Altan (altan. please visit www.Summary/Questions CPF CPF is supported by the National Science Foundation and 10+ member companies. CPF is conducting R&D in metal forming.