products in hot stamped boron steel/media/files/autosteel/great designs in steel... · w w w . a u...

w w w . a u t o s t e e l . o r g

PRODUCTS IN HOT STAMPEDBORON STEEL

Martin JonssonGESTAMP


Agenda

Overview Corporacin Gestamp

Hotstamping process

Ford Focus1 Front Bumper

Volvo XC90

Side Impact Beams

Rear Bumper

Structural Reinforcements


Corporacin Gestamp

Turnover: Approximately 2.400 Million .

Leadership:

European Group with presence in 14 countries in Europe and America

58 industrial plants worldwide.

Employs 11.200 people.

Steel Service Centers

Components, assemblies and systems for the automotive industry


Gestamp Automocin

Activity

Facilities

Employment

Leadership

2.003: 7.045 Employees. 2.004: 8.740 Employees.

Total Sales

32 Plants in UE 15. 5 Plants in Mercosur (Brasil and Argentina) 4 Plants in N. America (US and Mxico) 2 Plants in E.E.

Supply Metal Components to the OEMs.

Wide range of technologies. Different components for body & white structures Focus in weight reduction and increase of safety

In 2002: 1.025 Million . In 2003: 1.100 Million . In 2004: 1.250 Million approximately


Geographical Distribution

Gestamp HardTech Mason

Gestamp HardTech Lule


Strategic Products

Rear/FrontBeam ImpactSystems

A-B Pillar

Instrument Panel System

Subchassis Module

Closures

Pedal Assembly

Rear axle


Value Chain

Tailored weldedblanks

Blanking

Die toolsmanufacturingTailored weldedblanks

HydroformingStamping

Protection

Subassemblies &/ systems

Total collaboration with our clients:Right from the design anddevelopment phase, we set up project and simultaneousengineering teams to monitor thevalue chain, contributing ourindustrial know-how and experiencein all of the technologies andresponsibilities involved in theprocess.

Value chain


Customers 2004

Subassemblies &/ systems

Value chain

6%

1%

4%

1%10%

18%

22%

22%

10%

6%

Tier 1

Industrial vehicules

Tools and various


Gestamp HardTech

Lule

MasonDetroit

Stockholm

1998

1986

1974 Patent on hotstamping


Hot Stamping Process

Boron Steel

Alu coated Boron Steel

Shot Blasting


Materialdata Hot Stamped Boron Steel


Usibor 1500 Aluminum Coated

As delivered

After Hot Stamping

Al-layer (Hardness approx. 60 HV, thickness approx. 25 m )

Base metal (approx 185 HV)

Al/Fe-layer (approx. 800 HV)

Base metal (approx 470 HV)

Corosion Resistant No need for shotblasting


Products

Side Impact Beams Bumpers

Structural Reinforcements


R&D Lule

Full Service Supplier 1990 Side Impact Beams

1995 Bumper Beam Systems

Design, CAE, Prototyping and Testing

CAD

UG

IDEAS

CATIA V4, V5

CAE LS-DYNA

CRASH ANALYSIS

FORMING ANALYSIS

STATIC LARGE INTRUSION


Test Equipment

Beam Test Rig FMVSS214

Door Test Rig FMVSS214

Swick-Roell 600 kN Test Machine


Bumper Crash Test Facility


Crash Test Equipment

Crash track Speed 13.6 mph (21 km/h) with 3300 lb Speed 11 mph (17 km/h) with 5500 lbPendelum Speed 11 mph (17 km/h) with 2200 lb Speed 6.5 mph (10 km/h) with 5500 lbTest cart Weight 1540 5500 lb (700-2500 kg)Barriers

Pendelum AZT 40 % offset 0 o ,10 o

IIHS 0 o, 30 o and PoleData acqusition system Kayser-ThredeLoad ,displacement, speed and

accelerometer measurementHigh speed camera Red Lake

16.000 frames/s



Requirements ECE Pendelum 2.5 mph AZT 10 mph 40 % offset Minimize intrusion



BEAM

Hot Stamped Boron Steel

Thickness 1.5 mm

Weight 9.46 lb (4.3 kg)

FRONT PLATE

HSS Steel

Thickness 1.0 mm

Weight 2.16 lb (0.98 kg)

TOWING HOOK TUBE

Push through at crash

Weight 0.62lb (0.28 kg)

MOUNTING PLATE

Thickness 2.0 mm

Weight 2x0.64 lb (0.29 kg)TOWING HOOK PLATE

HSS

Thickness 2.0 mm

Weight 0.84 lb ( 0.38 kg)



Replace foam/ beam Bumper System to improve AZT crash test behaviour

14.3 lb (6.5 kg)14.3 lb (6.5 kg)


AZT (RCAR) 10 mph crashtest

Crash is triggered at barrier hitpoint

Section collaps under controlled load

Protect siderails from damage and minimize intrusion

The overall beam stiffness decreases during collapse which minimize bending of siderails from curved beam

Patented


AZT (RCAR) 10 mph crashtest


Performance comparisition

REDUCED INTRUSION 60 mm

0

10

20

30

40

50

60

70

80

90

100

0 20 40 60 80 100 120 140 160 180 200Intrusion [mm]

Bar

rier L

oad

[kN

]

Hotstamped beam

Coldformed beam with foam


Cooling airflow

Improved airflow to cooler with; Lower section height on backside of beam More outboard position in Y0


Research on IIHS Test

5 mph 0o barrier 5 mph 30o barrier

Intrusion 34 mm

Intrusion 66 mm


Volvo XC90

Weight Savings 33lb (15 kg) / vehicle


Volvo XC90 Front Side Impact Beam

Design Thickness 2.0 mm Weight 2.6 lb (1.8 kg)


Volvo XC90 Rear Side Impact Beam



Volvo XC90 B-pillar Reinforcement

Requirements Rollover crash load IIHS SUV barrier load

Design Thickness 2.0 mm Weight 14.9 lb (6.8 kg) Lasercut trim and holes



Forming analysis Coupled Thermal and Mechanical analysis Predict blankshape Evaluate excess material and material thinning Evaluate pressload and press settings



Section depth 95 mm

Section depth 52 mm

Tensile test

0

200

400

600

800

1000

1200

1400

1600

0 1 2 3 4 5 6 7 8 9

Strain [%]

Stre

ss [M

Pa]

Flange 1Sidewall 1Sidewall 2Flange 2


Volvo XC90 Roof Reinforcement



Volvo XC90 Rear Bumper

Back Panel Thickness 1.2 mm Weight 9.09 lb (4.13 kg) Lasercut trim and holes

Rear Bumper Beam Thickness 1.2 mm Weight 9.59 lb (4.36 kg) Lasercut trim and holes


Conclusions

Integrated Crossmember Excellent air flow for cooler Crash Energy Managment System Energy absorbtion without foam Design flexibility

Crossectional changes Deep Sections High sweep

Low weight Low stackup after crash Low intrusion

Very high formability Forming of complex geometries UHSS materialdata quenched High toughness High elongation at brake Material properties not dependent

of forming depth Good dimensional tolerances Good weldability Well suited for crash applications

Bumper BeamsHot Stamping Process

products in hot stamped boron steel/media/files/autosteel/great designs in steel... · w w w . a u...

Documents