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+ Avinash G 10ME61R03
+
Avinash G
10ME61R03

New developments in design and manufacturing automotive bulb shields

+ Avinash G 10ME61R03 New developments in design and manufacturing automotive bulb shields

+

CONTENT

n Introduction n Formability at Progressive Speed n Rigidity Improvement by Tailor-Welded Design n Drawing and Cosmetic Prediction n Global Manufacturing n Conclusion n References

+ CONTENT n Introduction n Formability at Progressive Speed n Rigidity Improvement by Tailor-Welded Design n

+

1. INTRODUCTION

Shield Leg
Shield
Leg

Bulb

Shield

Fig.1a

Bulb shield development has experienced three stages. During the 1990s, the original three-piece bulb shield created in the 1980s became a two-piece bulb shield design. From the late 1990s through today, a one-piece design has become the most popular.

+ 1. INTRODUCTION Shield Leg Bulb Shield Fig . 1a Bulb shield development has experienced three

+

1. INTRODUCTION CONTINUED ..

+ 1. INTRODUCTION CONTINUED .. 1.Bulb 2.Bulb Shield 3.Reflector Head Lamp Assembly Fig . 1b

1.Bulb

2.Bulb Shield

3.Reflector

Head Lamp Assembly

Fig.1b

+ 1. INTRODUCTION CONTINUED .. 1.Bulb 2.Bulb Shield 3.Reflector Head Lamp Assembly Fig . 1b

+

1. INTRODUCTION CONTINUED ..

n Understanding

the

sheet

formability

at

progressive

speed by design and conducting dome tests.

n Improving both rigidity and formability by tailor- welded design.

n Providing an accurate quote and reduce lead-time by FEM prediction deformation and cosmetic effect.

n Increasing economic efficiency by creating a global manufacturing structure.

+ 1. INTRODUCTION CONTINUED .. n Understanding the sheet formability at progressive speed by design and

+

2. FORMABILITY AT PROGRESSIVE SPEED CONTI ..

n In this study, the dome size is scaled down to a diameter of 71 mm, the size range of a common bulb shield.

n As we see from

fig.2a USI 75 ton press with a rocker arm

drive was chosen to

run

the test

at 45 strokes/min and

203.2 mm stroke distance. The maximum speed is about

27,432 mm/min. S I 7 5 Ton Press W ith a R ocker A rm D
27,432 mm/min.
S I 7 5 Ton Press W ith a R ocker A rm
D rive
U
+ 2. FORMABILITY AT PROGRESSIVE SPEED CONTI .. n In this study, the dome size is

Fig .2 a

1 . G as sp rin g ; 2 . Pu n ch ; 3 . B in d er; 4 : D ie rin g ; 5 . C ou n ter p u n ch

+ 2. FORMABILITY AT PROGRESSIVE SPEED CONTI .. n In this study, the dome size is

+

2. FORMABILITY AT PROGRESSIVE SPEED CONTI ..

+ 2. FORMABILITY AT PROGRESSIVE SPEED CONTI .. n The tested sheet steel is prepared into

n The tested sheet steel is prepared into six coupon shapes which are designed with width varying from 4 mm to 71 mm

n Twenty-five coupons are prepared for each shape. Ten coupons

are used to adjust the stroke till the necking happens.

Fifteen

coupons are etched

with 2.54

mm

grids using a Lectroetch grid marking system.

+ 2. FORMABILITY AT PROGRESSIVE SPEED CONTI .. n The tested sheet steel is prepared into

diameter circle

+

2. FORMABILITY AT PROGRESSIVE SPEED CONTI ..

n Fifteen coupons are etched with 2.54 mm diameter circle grids using a Lectroetch grid marking system.

n Major and minor engineering strains are measured by Mylar tape.

a. C ircle g rid s b . S train c. S train calcu lation m
a. C ircle g rid s
b .
S train
c.
S train
calcu lation
m
easu rem en t
+ 2. FORMABILITY AT PROGRESSIVE SPEED CONTI .. n Fifteen coupons are etched with 2.54 mm

+

2. FORMABILITY AT PROGRESSIVE SPEED CONTI ..

Minor engineering strain a. FLD of 0.762mm thick cold rolled steel CQ Major engineering strain
Minor engineering strain
a.
FLD of 0.762mm thick cold rolled steel
CQ
Major engineering strain

+

2. FORMABILITY AT PROGRESSIVE SPEED CONTI ..

Minor engineering strain Major engineering strain
Minor engineering strain
Major engineering strain

a.

FLD of 0.7mm thick AKDQ

+ 2. FORMABILITY AT PROGRESSIVE SPEED CONTI .. Minor engineering strain Major engineering strain a .

+

2. FORMABILITY AT PROGRESSIVE SPEED CONTI ..

+ 2. FORMABILITY AT PROGRESSIVE SPEED CONTI .. Major engineering strain Minor engineering strain a .
Major engineering strain
Major engineering strain

Minor engineering strain

a.

FLD of 1mm thick HSLA 450

+ 2. FORMABILITY AT PROGRESSIVE SPEED CONTI .. Major engineering strain Minor engineering strain a .

+

3. RIGIDITY IMPROVEMENT BY TAILOR- WELDED DESIGN

Leveling machine coile r Preparation of strip edges Pinch roll units feed Laser welding pinch coiler
Leveling machine
coile
r
Preparation of strip
edges
Pinch roll units
feed
Laser welding
pinch
coiler
Laser welding tailored strips

+

3. RIGIDITY IMPROVEMENT BY TAILOR- WELDED DESIGN CONTINUED ..

n Tailor-welded blank (TWB) technology was initially developed in the 1940s.

n TWB technology entails the welding of different steel sheet

types

and

processes.

thicknesses

together

prior

to

the

forming

n Bulb shield vibration durability can be improved significantly by choosing a stronger leg.

n The technology removes unwanted geometric variation by sequentially flattening the strip, evenly feeding speed control, edge preparation and sensor controls and inert gas protect laser welding.

+ 3. RIGIDITY IMPROVEMENT BY TAILOR- WELDED DESIGN CONTINUED .. n Tailor-welded blank (TWB) technology was

n The potential cost reduction over a two-piece assembly is estimated at 25–35%.

+

3. RIGIDITY IMPROVEMENT BY TAILOR- WELDED DESIGN CONTINUED ..

+ 3. RIGIDITY IMPROVEMENT BY TAILOR- WELDED DESIGN CONTINUED ..

+

3. RIGIDITY IMPROVEMENT BY TAILOR- WELDED DESIGN CONTINUED ..

+ 3. RIGIDITY IMPROVEMENT BY TAILOR- WELDED DESIGN CONTINUED .. Strip combinations in the tailored weld

Strip combinations in the tailored weld strip test

+ 3. RIGIDITY IMPROVEMENT BY TAILOR- WELDED DESIGN CONTINUED .. Strip combinations in the tailored weld

+

4. DRAWING AND COSMETIC PREDICTION

+ 4. DRAWING AND COSMETIC PREDICTION
+ 4. DRAWING AND COSMETIC PREDICTION
+ 4. DRAWING AND COSMETIC PREDICTION

+

4 DRAWING AND COSMETIC PREDICTION CONTI ..
4 DRAWING AND COSMETIC PREDICTION
CONTI ..
+ 4 DRAWING AND COSMETIC PREDICTION CONTI .. CDS : Contact surface under deformation FDS :

CDS: Contact surface under deformation FDS: Free-deformed sheet surface CMS: Contact surface under minute deformation

+

4 DRAWING AND COSMETIC PREDICTION CONTI ..

+ 4 DRAWING AND COSMETIC PREDICTION CONTI .. Nickel–Chrome plated physical part Predicted Comparison of prediction
+ 4 DRAWING AND COSMETIC PREDICTION CONTI .. Nickel–Chrome plated physical part Predicted Comparison of prediction
Nickel–Chrome plated physical part
Nickel–Chrome plated physical
part

Predicted

Comparison of prediction and physical parts

+

4. DRAWING AND COSMETIC PREDICTION CONTI ..

+ 4. DRAWING AND COSMETIC PREDICTION CONTI .. n The cosmetic appearance of a bulb shield

n The cosmetic appearance of a bulb shield has previously been unknown until physical parts are produced from the progressive tool and subsequently electroplated.

n Commercial

FEM

simulation

codes

provide

us

with the

capability to design and analyze the progressive draw at

the early stage of tool development.

n Using the output

data from the FEM drawn simulation,

we

propose a cosmetic prediction method to predict the cosmetic appearance of the drawn sheet metal part.

+ 4. DRAWING AND COSMETIC PREDICTION CONTI .. n The cosmetic appearance of a bulb shield

+

5. GLOBAL MANUFACTURING
5. GLOBAL MANUFACTURING

Global manufacturing structure for progressive tool and bulb shield production

+ 5. GLOBAL MANUFACTURING Global manufacturing structure for progressive tool and bulb shield production

+

5. GLOBAL MANUFACTURING

+ 5. GLOBAL MANUFACTURING n Global manufacturing means producing products at low cost, on short notice,

n Global manufacturing means producing products at low cost, on short notice, and in high quality by optimally organizing resources on a global scale.

n FEM simulation is extensively employed in the quote, design and later tryout stage and internet provides connection between engineers and management, the potential risk of defects can be foreseen and avoided at an earlier stage.

n One additional advantage of the structure: because of the time difference between US headquarters and overseas tool supplier, it is possible to make full use of 24 hours.

+ 5. GLOBAL MANUFACTURING n Global manufacturing means producing products at low cost, on short notice,

+

CONCLUSION

+ CONCLUSION n Automotive bulb shield manufacturing is facing many challenges. Several technologies have been developed

n Automotive bulb shield manufacturing is facing many challenges. Several technologies have been developed at the Isatec Technical Center, a Cleveland-based engineering company, to tackle the challenges.

n Dome tests at progressive speeds are designed to understand the sheet materials’ formability.

n Tailored weld strip design is proposed to improve the vibration durability of the product without sacrificing the one-piece design benefits.

n FEM simulation- based cosmetic prediction method is proposed to predict not only the success of the draw design but also the cosmetic effect of the drawn part.

n

A

global manufacturing structure is created to manufacture tool and conduct production at lost cost and a timely manner.

n

+ CONCLUSION n Automotive bulb shield manufacturing is facing many challenges. Several technologies have been developed

As a result of this application, the year of 2006 has seen a double-digit profit and sales growth of US $5 million

+

REFERENCES

+ REFERENCES n Z. Q. Sheng & M. Strazzanti , New developments in design and manufacturing

n Z. Q. Sheng & M. Strazzanti, New developments in design and manufacturing automotive bulb shields, 22 March 2007 / Accepted: 17 September 2007 / Published online: 17 October 2007 Springer-Verlag London Limited 2007

+ REFERENCES n Z. Q. Sheng & M. Strazzanti , New developments in design and manufacturing

+

 Thank you
 Thank you