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Name : Nur Liyana Binti Tajul LileAge : 31 Nationality : Malaysian

Educational background

Year Institution Qualification

2004-2008 International Islamic University Malaysia Bachelor of Engineering

2008-2009 Universiti KebangsaanMalaysia

Master of Engineering (Mechanical)

Working experiences

Year Company Position

2009-now Universiti Malaysia Perlis Junior lecturer

2013-2016 Toyohashi University of Technology Doctoral student

Personal background

1

Successive Forging of Quenchable Steel, Aluminium and Stainless Steel Sheets having

Thickness Distribution and Inclined Cross-SectionChapter Contents

1 Introduction

2 Successive forging of tailored blank having thickness distribution

3 Improvement of surface quality of tailor-forged blank produced by successive forging by optimization of punch shape

4 Hot stamping of roof rail from tailored blank having thickness distribution

5 Local thickening of aluminium and SPCC sheets by beading and compression

6 Successive forging of aluminium and stainless steel long sheets having inclined cross-sections

7 Future perspectives2

Global emissions

3

Mode of transportation

Emission TgCO2

Share [%]

Road 4282 72.3Rail 124 2.1

Maritime Shipping

626 10.6

Aviation 688 11.6

Emissions of CO2 in year 2000

国土交通相H22年度国内メーカー燃費一覧

05

10

15

20

25

30

35

500 1000 1500 2000 2500Weight of vehicle [kg]

Fuel

con

sum

ptio

n[k

m/L

]

Standard size car

Hybrid

1km/L improvement in -100kg

1.4km/Limprovement

E. Uherek et al. Transport impacts on atmosphere andclimate: Land transport, Atmospheric Environment,44 (37) (2010), 4772-4816.

Lightweight technologies of automobiles

4

Hollow structuredMaterial placement

Optimization of thickness distribution

Structure optimization

Aluminium alloysMagnesium alloysHigh strength steel

Lightweight metals27%

28%10%3%

28%

4%

Body-in-whiteInterior

Chassis group

Others

Powertrain group

Glass

Pie chart of weight fraction of passenger car

A. Kelkaret et al, Automobile Bodies: Can Aluminum Be anEconomical Alternative to Steel?, The Journal of The Minerals,Metals & Materials Society, 53 (8) (2001), 28-32.

Tailored blanks

5

Tailor rolled blankTailor welded blank

Tailor patchwork blank

Tailored heat treated blank

Combines different grades, thickness, materials, coatings and material properties

Hot stamping

6

Reduce flow stressImprove formability

High strengthReduce springback

Furnace heating

Transfer Transfer

Hot stampingHot-stamped part

22MnB5

Hot stamping of quenchable steel sheets

7

Centre pillar

Roller feeder

Sheet

High temperature

Below austenitic temperature; no quenching

Above austenitic temperature; quenching

Low temperature

Tailoring in hot stamping

High temperature; low cooling rate

Upper die

Lower die

Low temperature; high cooling rate

Tailored die quenching

Tailored tempering

Problems in tailored blanks and high strength steel

8

Tailor rolled blank

Rolling mill and controlling system are not commonly

available

Tailor welded blank

Change in propertiesStress concentration

Tailored blanks High strength steel

Large forming loadLow formabilityLarge springback

Short tool life

High-Strength Steel (340-440 MPa)Advanced High-Strength Steel (590-780 MPa)Ultra high-strength Steel (980-1180 MPa)

hondanews.com

Successive Forging of Quenchable Steel, Aluminium and Stainless Steel Sheets having


1 Introduction







Successive forging of tailored blank having thickness distribution

Tailor welded blank Tailor rolled blank

Rolling mill and controlling system are not commonly

available

Sheet

Tailored blankForging

Change in propertiesStress concentrationImprove material utilization

Strength improvementWeight reduction

Tailored blank

Successive forging of tailored blank

To produce tailored blanks having a thickness distribution by adjusting the feeding interval using successive forging 10

Approach of successive forging

11

Sheet

Successive forging

PressUpper punch

LowerpunchFeed

Tailor-forged blankThin Thick

Thick

Upper punch

Lower punch

Blank

Compression Feeding Compression

Feed

Reduction in thickness of blank by elastic deformation of press and tools

12

Small contact area

Reduction in thickness: large

Feed

(b) Small feeding

Small deflection Large deflection

Reduction in thickness: small

Lower punch

Upper punch

Press

(a) No compression

Large contact area(c) Large feeding

Tools dimensions, successive forgingconditions and material composition

13

Feed

Sheet

Feeder

Lower punch

10

Upper punch

1.6

R1

C Si Mn P B0.21 0.25 1.2 0.015 0.0014

Stroke = 2.1 mm

Feed per one strike, f

22MnB5 composition [%]

Upper punch

Lower punch

FeederSheet

Successive forging of tailored blanks

14

Successive forging of tailored blanks

15

Thickness distribution of tailored blank by successive forging

16

Thic

knes

s [m

m]

Distance from sheet edge x [mm]

f = 1 mm, 130 times

0.5

1

1.5

2

0 50 150 200 250100

Steady-state

Start of compression

Transient

x0

Compression f = 1 mm, 130

times

Tool marks

195 mm

5 mm

Transient zone

Feeding direction

Steady-state reduction in thickness andsteady-state forging load

17

0

200

400

600

800

1000

0

10

20

30

40

0 2 4 6 8

Constant feed f [mm]

Red

uctio

n in

thic

knes

s r[%

]

Forg

ing

load

[kN

]

Reduction in thickness

Forging load

0 2 4 6 8

10

20

30

800

400

0

40

1000

200

600

Steady-state thickness t of compressed blank 96.0046.0 ft mm

Control of thickness distribution intransient regions

18

0 10 20 30 40 50

Thic

knes

s [m

m]

Distance from sheet edge [mm]

f = 7 mm

0.5 mm

0.1 mm

604020

1

0.50

1.5

3010 50Th

ickn

ess [

mm

]Distance from sheet edge [mm]

0.5

1

1.5

0 20 6040

fv = 1 2.5 4 5.57 mm

fv = 1 2 3 4 5 6 7 mm

fv = 1 4 7 mm

30 5010

(a) Decreasing thickness(Constant feed f)

(b) Increasing thickness(Variable feed fv)

Tailored blank with feeding control in transient region

19

Thic

knes

s [m

m]

Distance from sheet edge [mm]

No control

0

Control

100 150 200 2500.5

1.5

2.0

1

50

Feed paths with and without feeding control

20

Feed

per

one

strik

e [m

m]

Total amount of feed [mm]

Control

No control

0 50 100 150

3

6

9

1

1.3Feed 1 mm

0.1 mm

Thic

knes

s [m

m]

Sheet length [mm]30 15090 150 190Th

ickn

ess [

mm

]

Sheet length [mm]

1

1.3

fv= ∆1.5 mm

1 mm

Overshoot Feed incrementTo obtain sharp change of slope To obtain gradual

change of slope

Conclusions

• The thickness distribution of tailor-forged blanks wascontrolled by adjusting the feed under a constant punchstroke.

• The transient regions of decreasing and increasingthickness showed dissimilar pattern.

• Constant and variable feeds were utilized to control thethickness distribution in the transient region.

21

Successive Forging of Quenchable Steel, Aluminium and Stainless Steel sheets Having


1 Introduction







Improvement of surface quality of tailor-forged blankproduced by successive forging by

optimization of punch shape

Improvement of surface quality of tailor forged blank by optimization of punch shape

23

Surface markings

Compression

No compression

No compression

Problem with tailor-forged blank

Upper punch

Lower punch

Press

Inclined

Successive forging

Punch shape

Punch shapes and FEM conditions

24

10

C1

(b) Chamfer 10

R

(a) Corner radius

R = 1, 2.5, 3 and 5 mm

Radius of punch is change to improve the surface quality

Optimisation of punch shapes

25

Upper punch

Sheet

Lower punch

Finite Element Method

26

Upper punch

Lower punch

Sheet

Finite Element Method

27

Tools for correcting inclination

28

Concave and convex plates

Spring

(b) Tools for correcting inclination

Decrease in inclinationR450

(a) Tools without correcting inclination

InclinedUpper punch

Lower punchPress

Tools dimensions, successive forgingcondition and material composition

29

Upper base plate

Convex and concave plate

Middle base plate

Lower base plate

210SpringUpper punch

Lower punchSheet

C Si Mn P B0.21 0.25 1.2 0.015 0.0014

Stroke = 2.4 mm

22MnB5 composition [%]

Punch deflection

30

(a) Without incline correctionSmall contact area

Upper punch

Sheet

Lower punch

Upper punch

Lower punchBlank

0.61 mm

Large contact area(b) With incline correction 0.07 mm

Surfaces of tailored blank for f = 5mm with incline correction and corner

radius punch 1 mm

31

-0.04

-0.02

0

0.02

0.04

0 5 10 15Distance from sheet edge [mm]

Hei

ght[

mm

]

With correction

Without correction

Reflected stripe pattern

Surface height of tailored blank for f = 5mm with incline correction

32

5 10 15

0.04

0.02

0

-0.02

-0.04

Sheet length [mm]

Hei

ght[

mm

]

0 5 10 15

0.04

0.02

0

-0.02

-0.04

Sheet length [mm]H

eigh

t[m

m]

0

(a) Corner radius 3 mm (b) Chamfer 1 mm

Conclusions

• The die without incline correction produced tailoredblank having thickness distribution with surfacemarkings due to the upper die incline duringcompression.

• The misalignment between the upper and lower dies wasreduced with the incline correcting die, and the uppersurface quality was improved.

• The die with incline correction together with the cornerradius punch minimize the surface markings on thetailored blank

33

Successive Forging of Quenchable Steel, Aluminium and Stainless Steel Sheets Having


1 Introduction







Hot stamping of roof rail from tailored blankhaving thickness distribution

To produce miniature of roof rail from successively-forged blank by hot stamping

35

Hot stampingSheet

Successive forging

Press Upper punch

Lower punchFeeding Tailor-forged

blank

Thin Thick

Thick

Improve material utilization


Tailored blank

Improve formability

High strengthReduce springback

Hot stamping

Roof rail dimension, hot stamping conditions and material composition

36

C Si Mn Al B Ti Cr

0.23 0.27 1.22 0.04 0.0032 0.0037 0.2

Chemical composition of Al-Si coated quenchable steel [%]

Heating temperature 910 oC

Heating time 240 s

Holding time at bottom dead centre 10 s

Conditions for hot stamping

90(b)

100

t =1.0

t =1.6

(a)

1mm

Procedure of hot stamping of roof rail

37

Lower die

Cushion pin

Upper die

Front view

Heating temperature [℃] 910

Heating time [s] 240

Heating condition

Furnace


38

Upper die

Front viewFurnace



Heating condition


39

Transferring[5s]

Front viewFurnace



Heating condition

1mm


40

Front viewFurnace



Heating condition

1mm


41

Holding at bottom dead center [10s]

Front viewFurnace



Heating condition

Thickness distribution of hot-stamped roof rails

42

Uniform thickness

TailoredThic

knes

s [m

m]

Distance from roof rail edge x [mm]0 50 100 150 200 2500.5

1.5

2.0

1x0

(c) Cross-section

No compression

Compression

(b) Uniform thickness roof rail

Compression

(a) Tailored roof rail

No compression

Curvature and surface coating

43

Distance from roof rail edge x [mm]50 100 150 200 2500

Diff

eren

ce o

f hei

ght,

z [m

m]

Before hot stamping

After hot stamping

-3

-1

1

3

5

xz

0

(a) Before hot stamping

(b) After hot stamping

23.5 µm

50 μm

Compressed area

14.2 µm

50 μm

Compressed area

29.2 µm

50 μm

Non-compressed area

25.8 µm

50 μm

Non-compressed area

Weight and hardness of tailor-forged roof rail

44

(a) Uniform thickness90

323 g

(b) Tailored blank90

257 g

AD

EB C

Vic

kers

har

dnes

s [H

V20

]

Points of measurementDCBA E

200

500

0

600

400

300

100

Before hot stamping

After hot stamping

1.6 mm (non-compressed)1.0 mm (compressed)

Conclusions

• The tailored blank having two thicknesses was successfullyhot-stamped into a roof rail miniature.

• The Al-Si coating remained on the surface of the quenchablesteel sheet after forging process.

• The strength of the hot-stamped tailored roof rail increasesremarkably with a reduction in weight.

45



1 Introduction







Local thickening of aluminium and SPCC sheets by beading and compression

Development of sheet forging process having different thicknesses with the thick portion having higher strength

47

Improve material utilization


Tailored blank

Tailor rolled blank

Thick part withlow strength

Workhardening

Thin part withhigh strength

Approach of local thickening of sheet by beadingand compression

48

punch

die

sheet

1st stage for beading

floating die

blank holder

spring

2nd stage for compression

punch

Tools dimensions, thickening conditions and material properties

49

blank holder

20

100

spring

floating die

Compression die

20

R1

R2

10

Beading die

Beadingpunch

Material Aluminium A1050 SPCCTensile strength [Mpa] 105 334Hardness [Hv] 31 95Sheet thickness t [mm] 0.5, 1.0, 1.5 0.5, 1.0Sheet length [mm] 50Sheet width [mm] 101.0 103.5 108.5

Beading die height h [mm] 3 5 8

α=180o

α=90o

α =120o

α

α

Local thickening of aluminium sheet with beading die α=1800

50beading

h = 5 mm

h = 8 mm

h = 3 mm

Thickening

compression

Folding

t = 1.0 mm

Thickening behavior for aluminium sheet at different strokes for beading die α=1800

51

h= 5 mms =0.0 mm s =1.8 mm

s =3.5 mm s =5.0 mm

s =0.0 mm s =1.8 mm

s =3.5 mm s =4.8 mm

h= 8 mm

t= 1.5 mm

Cross-section of sheet having local thickening

52

h =5 mm, t =0.5 mm

h =5 mm, t =1.0 mm

h =5 mm, t =1.5 mm

h =8 mm, t =1.0 mm

Thickening region

53

Thickness and strength distributions of sheet havinglocal thickening

0

200

400

600

800

0.95

1.2

1.45

1.7

1.95

Strength

Thickness

h =8.0 mm

h =5.0 mm

h =3.0 mm

1.95

1.7

1.45

1.2

0.95

800

600

400

200

00 20 40 60 80 100

Thic

knes

s [m

m]

Stre

ngth

[MPa

.mm

]

x0

Distance from sheet edge x [mm]

Strength was estimated as a product of the flow stress and thickness

54

Effect of beading height and die shapeon thickening

Max

imum

cha

nge

in th

ickn

ess [

%]

Beading height h [mm]

Aluminum α =1200

Aluminum α =180o

Aluminum α =90o

SPCC α=180o

SPCC α =90o

SPCC α =1200

1 2 3 4 5 6

50

40

30

20

0 7 8 9 10

10

Conclusions

• The sheet having local thickening can be produced by beadingand compression.

• For a small beading height, beading die 180o produces largerlocal thickening compared to beading die 90o and 120o.

• For a large beading height, beading die 90o produces sheethaving local thickening without folding. The strength of thethick portion is larger than the thin portion.

55



1 Introduction







Successive forging of aluminium and stainless steel long sheets having inclined cross-sections

To develop a successive forging process of long sheet with reduction in forging load, waving and curvature.

57

Rolling

Wrinkling

Repetitive loading with specific feeding

of blank into the punch

Loading

PunchCurvature

sheet forging

Large loadCleaning blade

Printer cartridge

Developer roller

OPC drum

Punch

Die

sheet

Steps in successive forging of long sheet

58


59


60


61


62


63


64


65


66


67


68


69


70


71


72


73


74


75


76

Tools dimensions and forging conditions

77

Punch

Die

Entrance guide

Side guide

Feeder

sheet

Upper guide

(b) Taper bottom punch

1022 6

(a) Flat bottom punch

1033

Side view Front view

ConditionsAluminum

A1050Stainless steel SUS

430Forging interval f /mm 3, 5, 10, 20 1, 3, 5Amount of feed /mm 200Average punch speed /mm･s-1 20 Reduction in thickness at punch tip/mm

1.2 1.1

Successive forging of inclined long sheet forforging interval f=5mm using taper punch

78

Entrance guide

sheet

Punch

Die

Successive forging of inclined long sheet forforging interval f=5mm using taper punch

79

Waving, depression and curvature observation for forging interval f= 5 mm

80

(a) Flat punch (b) Taper punch

AA’

Waving

Section A-A’

0.3 mm Depression

B B’

Section B-B’

0.3 mm

Forged aluminium sheets having inclined cross-sectionwith exit guide and taper punch for t = 2 mm

81

(b) f= 5 mm

10.35

5.88o0.84 1.83

(a) f= 3 mm

10.48

0.79 1.785.80o

A A’ B B’

Average width difference and forging load

82

Aver

age

wid

th d

iffer

ence

W1-

W2

[mm

]

0

0.5

1.0

1.5

5 10 15 20Forging interval f [mm]

Flat, t = 2 mm

Flat, t = 3 mm

Taper, t = 3 mmTaper, t = 2 mm

w1

w2

Forging interval f [mm]

Forg

ing

load

[kN

]5 10 15 200

10

20

30

40

Flat, t = 3 mm

Flat, t = 2 mm

Taper, t = 3 mmTaper, t = 2 mm

Forged stainless steel sheet with differentforging intervals

83

(a) f= 1 mm

Burr

(b) f= 3 mm (c) f= 5 mm

0.83 1.685.39o

10.18

5.44o0.86 1.71

10.05

Section A-A’ Section B-B’ Section C-C’

C C’A A’ B B’

Groove die tool dimension

84

sheet

5

10.5

Front view

Die

Punch

DieFeeder

sheet

Upper guide

Forged stainless steel sheet with differentforging intervals using grooved die

85

(c) f= 5mm(b) f= 3mm(a) f= 1mm

A A’ B B’ C C’

Section A-A’ Section B-B’

0.88 1.755.40o

9.46

Section C-C’

5.76o0.90 1.76

9.43

wavy

Conclusions

• The inclined long sheet which is conventionally producedby milling and rolling process can be produced by forgingprocess.

• The depression of the forged sheet was reduced with thetaper bottom inclined punch.

• As the forging interval decreases for the taper bottominclined punch, the waving of the forged sheet wasdecreased.

• The curvature and burr of the forged sheet were preventedby the grooved die.

86



1 Introduction







Future perspectives

Application of tailored blank having a thickness distribution for car body panels and parts

88

Thickness in two directions

New punch shapes and movement

LongitudinalLateral

2D profile tailored blank

Control of transient region and length distribution

Thic

knes

s [m

m]

Distance from sheet edge [mm]0

Transient region

100 150 200 2500.5

1.5

2.0

1

50

Length

Flexible cross-sectional shapeAutomatic feeding history

Journals

• Liyana Tajul, Tomoyoshi Maeno, Ken-ichiro Mori, Incremental forging of long plates having inclined cross-section and local thickening, International Journal of Mechanical & Mechatronics Engineering, 16 (3) (2016), pp. 34-52.

• Liyana Tajul, Tomoyoshi Maeno, Takaya Kinoshita, Ken-ichiro Mori, Successive forging of tailored blank having thickness distribution for hot stamping, The International Journal of Advanced Manufacturing Technology, (2016), doi:10.1007/s00170-016-9356-z.

International Conferences • Liyana Tajul, Tomoyoshi Maeno, Ken-ichiro Mori, Successive forging of long plate having

inclined cross-section, Procedia Engineering, 81 (2014), pp. 2361 – 2366.

• Liyana Tajul, Tomoyoshi Maeno, Takaya Kinoshita, Ken-ichiro Mori, Successive forging of tailored blank having thickness distribution for hot stamping, JSTP 7th International Seminar on Precision Forging, Nagoya, Japan, 9-12 March 2015.

List of publications

89

Japanese Conferences

• Liyana Tajul, Tomoyoshi Maeno, Ken-ichiro Mori, Takaya Kinoshita, Successive forging of long plate having inclined cross-section, The 64th Japanese Joint Conference for the Technology of Plasticity, Osaka, Japan, 1-3 November 2013.

• Liyana Tajul, Tomoyoshi Maeno, Ken-ichiro Mori, Takaya Kinoshita, Forging of plate having local thickening using beading and compression, The 2014 Japanese Spring Conference for the Technology of Plasticity, Tsukuba, Japan, 6-8 June 2014.

• Liyana Tajul, Tomoyoshi Maeno, Takaya Kinoshita, Ken-ichiro Mori, Control of thickness distribution in successive forging of tailored blank for hot stamping, The 65th Japanese Joint Conference for the Technology of Plasticity, Okayama, Japan, 11-13 October 2013.

• Liyana Tajul, Tomoyoshi Maeno, Takaya Kinoshita, Ken-ichiro Mori, Improvement of surface quality of tailor forged blank produced by successive forging for hot stamping by incline correcting die, The 2015 Japanese Spring Conference for the Technology of Plasticity, Yokohama, Japan, 29-31 May 2015.

List of publications

90

Thank you

91

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