new sheet metal forming technologies - techtank...feeder transfer to press temperbox® 30–70...

NEW SHEET METAL FORMING TECHNOLOGIESDr. Michael Machhammer

Innovativ Forming och PressningOlofström, Sverige

Content

- TemperBox®

- Servo-Hydraulic Press

- Hot Forming of High Strength Aluminum

TemperBox®Servo-Hydraulic Press

Hot Forming of High Strength Aluminum

Process definition partial hardening

AC3

AC1

Tem

pera

ture

Time

High strengthDuctile

Fully austenized

Ferrite/Pearlite


Austenization in MLF Furnace930°C / 330 Sec.

TemperBox®

930°C / 90 Sec.Cooling in

air

Time (sec.)

Tem

pera

ture

°C

Not coveredCovered


Hydraulic pressForming and quenching

AustenizationHeat in AP&T MLF870°C + min. 75

seconds

Handle blank with furnace

feeder

Transfer to press

TemperBox®

30–70 seconds(depending on sheet

thickness)

B-pillar – Gedia prototype production line

> AC3 780°C (not covered)

< AC1 723°C (covered)

In cooperation with

Hardness results

Hardness requirements:

Hard: 400–520 HV (acc. VW-TL4225)

Soft: 170–250 HV (acc. VW-TL4225)

25 mm(Acc. TL4225)

In cooperation with

Hardness results: Flange / Shoulder

Soft zone (< 205 HV)

Transition zone (205-400 HV)

Hard zone (> 400 HV)

Mask edge

Version 1

0 4 168 2012

Version 2(Hard flange and radius)

< 205 HV 205-400 HV

> 400 HVMask edge

8 12 2416 20

246 269 406328 374Hardness [HV]:

Measure [mm]:

188 190

0 4

Area for mechanical cutting (350-375 HV)In cooperation with

TemperBox® solutions

One (1) TemperBox®

integrated into a 5xMLF unit

Dual TemperBox®

Stand alone unit

TemperBox® Line solution for new MLF PH lines

▪ Footprint for MLF furnace with TemperBox® approx. 16 x 16 meters

▪ Two (2) double furnace feeders enable a 10-second cycle time

▪ One (1) TemperBox® integrated into a 5xMLF unit

▪ 4 units requested for approx. 12-second cycle time

Cost comparison

Cost per part TemperBox® Tailored temperingwith partially heated tool TWB

Soft bottom 100% 112% 126%

Advantages and

disadvantages of process

• Cycle time neutral• High precision of

transition areas• No thermal distortion• High design

flexibility• High repeatability• Short product

change time and low cost per product

• High precision of transition areas

• High thermal distortion• Limited design freedom • High scrap rate (geometry)• High tool wear (≈ 600°C

tool temperature)• High and extensive tryout

procedure

• Cycle time neutral• High precision of

transition areas• No thermal distortion• Limited design

freedom • Expensive

Soft

Hard

B-pillar with max 30 mm transition zone

In cooperation with

Content

- TemperBox®





Drive Concept

What defines a servo hydraulic press?

Performance

High Precision

0

400

0 1

Spee

d R

AM [m

m/s

]

Time [s]Servo_hydraulic_Press Conventional_hydraulic_Press

Speed drop / peak

Speed drop

Smooth transition at speed change point

Longer period of low speed →inhomogeneously temperature distribution

Shorter period of low speed

Possibility of splits!

No risk of splits!

Conventional hydraulic press:Servo hydraulic press:

Possibility of splits!No risk of Splits!

Servo hydraulic pressSmooth transition - change of acceleration and decelerationEnhancement on formability at the very end of the forming process

Active Parallel Control

Δy (mm)

F 0,2mm @ 300mm/s

Lab Test

Slide PositionSlide TiltPressure RightPressure Left

3.000mm

630 to2x 50to

1.100mm

20 - 40 to

Parallel Regulation

ONOFF

Fast Cycle Time

» Same top speed (800 mm/s)

» Cooling time 5 s

» Higher Accelerations

» Difference: 8.9 s vs 10.2 s

» Cycle time reduction: 1.3 s10,2 s

Fast

app

roac

h 1,

2s

Ret

urn

1,6s

Fast

app

roac

h 2,

1s

Ret

urn

2,0

s

8,9 s

Reduced Energy Consumption

To energy storage

Used from energy storage

0

0,1

0,2

0,3

0,4

0,5

0,6

Conventional ServokWh/Stroke 0,54 0,15

Advanced Press Modes

» Pulsating Mode Advanced

RB

RSt

a

Δs

Step Explanation Unit Value

PSt Restrike Start Position from TDC mm 400.0

RB Restrike Bottom Position from TDC mm 500.0

a Restrike Amplitude mm 2.0

Δs Zero Level Offset mm 25.0

Restrike Mode Enable

0

1

2

3

4

5

6

7

8

0

» High Output - SPM» High Repeatability

» Low Energy Consumption

» Reduced Maintenance» High Precision

Conclusion

Content

- TemperBox®





Aluminium activities at AP&T

2015

LOCOLITE FIAT

Tribology Study

LOCOLITE LOTUS

AP&T B-PillarTOOL

TEST ”HAT PROFILE”

LOCOMATECH APost Tool

Hot Forming Aluminum Test Center – AP&T

TCO study

Cross Die Test Tool

Door Ring Test Tool

High Strength 7xxx Aluminum Alloys: Design and Business Case for Automotive ApplicationsDr. Axel Förderreuther, Novelis, Christer Bäckdahl, AP&T GroupBad Nauheim, April 2019

2013-2015

2015-2016

2017

2019

2018 - 2019

2017 - 2018

Study Process Routes – AA7075

Time [h]

Specimen

Tem

pera

ture

[°C

]

SHT

Pre-aging

~AA7xxx – T6

after a couple of days

120 min

150 °C

3-step Paint bake

Storage

No time limit

0

5

10

15

20

25

30

0

100

200

300

400

500

600

AA7075: Pre-aged AA7075: After paint baking

A, E

long

atio

n at

frac

ture

, %

Stre

ngth

, MPa

YS

UTS

Ef

Process route for low volume production – AA7075 AMAG

AP&T Bpillar / Cut out Position Test Samples

Diagram: Mechanical Properties AA7075 / AMAG – Pre-Aged, Paint baked

AP&T Line Layout – Low Volume Production

Yield Strength

Elongation at fracture

Ultimate Strength

Time [h]

Tem

pera

ture

[°C

]

SHT

Pre-aging

~AA7xxx – T6

Directly after quenching

30 min

130 °C

3-step Paint bake

Storage

No time limit

0

5

10

15

20

25

30

0

100

200

300

400

500

600

AA7075: Pre-aged AA7075: After paint baking

A, E

long

atio

n at

frac

ture

, %

Stre

ngth

, MPa

YS

UTS

Ef

Specimen

Process route for high volume production – AA7075 AMAG

AP&T Line Layout – High Volume Production

AP&T Bpillar / Cut out Position Test Samples

Diagram: Mechanical Properties AA7075 / AMAG – Pre-Aged, Paint baked

Yield StrengthElongation at fracture

Ultimate Strength

Cost Study

Weight BIW: 274.5kgPress hardened steel (PHS): 25.4%Advanced high strength steel (AHSS): 15.5%High strength steel (HSS): 30.3%Mild steel (MS): 25.5%

Weight BIW: 220.0 kg (-20%)PHS & AHSS -> HS AluUpgauge by 50%Rocker, front longitudinals and rear bumper in s650. Roof rails and seat cross members: s701. HSS & MS: Leave as is.

Weight BIW: 192.2 kg (-30%), (-43% considering the parts substituted)s701 T6 (7xxx): 19.9%s650 (6xxx): 13.3%5754 (5xxx): 18.8%Upgauge by 30-100%Rocker, front longitudinals and rear bumper in s650. Roof rails and seat cross members: s701. All MS parts switched to 5754.HSS: Leave as is. 43.3%

Original: Golf 7 Level 1 substitution: Level 2 substitution:

© Novelis 2019

Complete BIW with 7xxx safety cell

The maximum x-intrusion occurs just below the steering column

Results from Crash: I.E. Front ODB

© Novelis 2019

Base Level 1 Level 2Weight BIW [kg] 274.5 220 192.2

Front ODB Dash intrusion [mm] 40.3 42.2 32.1Side IIHS B-pillar intrusion [mm] 275 314 271Side Pole B-pillar intrusion [mm] 194 193 173

Roof Crush SWR 4.6 4.2 4.9

High Volume Scenario: 1M parts per year

Materialloading

Materialheating

Pre-cooling

FormingTrimming 2x

Washing & Pre-

Treatment

Loading in

CarriersArtificial Ageing

Unloading

Washing requirements depend on the type of lubricant used in hot forming. The batch pre-treatment assumed is a conversion coating targeting bond durability for most specifications. The length of the ageing furnace depends on ageing times which will vary for different alloys. Different sections of the line can be operated separately i.e. trimming and washing/pre-treatment/ageing.

Parts Compared in TCO Calculation

Part Box Size [mm] Gauge St / Al [mm]* Weight St / Al [kg] Parts / Stroke St / Al

B-Pillar 1096 x 533 x 232 1.85 / 2.8-3.1 5.7 / 3.1-3.3 2 / 2

Roof Rail 1060 x 256 x 124 1.5 / 2.3-2.6 2.07 / 1.1-1.2 2 / 2

A-Pillar 768 x 553 x 164 1.0 / 1.6-1.8 2.56 / 1,4-1,6 2 / 2

Rocker reinf. 1551 x 183 x 070 1.1 / 1.7-1.9 2.89 / 1.5-1.7 4 / 4

Door SIBsingle hat 1027 x 042 x 091 1.5 / 2.2-2.5 1.14 / 0.6-0.7 4 / 4

Door SIBdouble hat 1037 x 047 x 128 1.2 / 1.9-2.1 1.75 / 0.95-1.05 4 / 4

Gauges for aluminum calculated to reach weight savings of 38-47%© Novelis 2019

High Volume TCO Calculation: 1M parts / Year

Part Utilization Steel Usibor Aluminum 7xxxPiece Price and Value In Use (VIU)

Piece Price Gauge +70%, s701

€/kgsaved, s701

Gauge +55%, s702

€/kgsaved, s702

B-Pillar 68% 100% +98% 5.98 +92% 4.96

Roof Rail 56% 100% +54% 4.99 +47% 3.71

A-Pillar 79% 100% +82% 5.79 +68% 4.07

Rocker reinf. 85% 100% +83% 4.36 +69% 3.12

Door SIB single hat 54% 100% +78% 5.80 +62% 3.90

Door SIB double hat 72% 100% +97% 5.35 +82% 3.94

A light weighting cost of 3-4€/kg saved can be reached in high volume with optimizing material utilization. Next Gen 7UHS offers better VIU due to down gauging and also quicker ageing times compared to s701. Secondary effects from joining and assembly have not been considered.

Application

AP&T Door Ring – Design

Based on a door ring geometry:

Complex design elements were integrated:

Many iteration loops together with FEM simulation were executed:

Final Tool:

AP&T Door Ring – AA6016 Cold Forming & 22MnB5 Hot Stamping

AA6016-Cold Forming / COF: 0.14 lubricated

High possibility of splits!

22MnB5 – Hot StampingCOF: 0.45

AA7075:

AA7075 – Hot FormedLubricated Tools

Chassis component manufactured through hot forming of high strength aluminium - New generation spring Link – Hydro 6070d

Content

- TemperBox®





new sheet metal forming technologies - techtank...feeder transfer to press temperbox® 30–70...

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