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By Dr. Eren Billur, Post-doctoral Researcher and Dr. Taylan Altan, Director and Professor Presented at ESI Hot Forming Die Engineering Seminar October.

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Presentation on theme: "By Dr. Eren Billur, Post-doctoral Researcher and Dr. Taylan Altan, Director and Professor Presented at ESI Hot Forming Die Engineering Seminar October."— Presentation transcript:

1 By Dr. Eren Billur, Post-doctoral Researcher and Dr. Taylan Altan, Director and Professor Presented at ESI Hot Forming Die Engineering Seminar October 15 th, 2013 Center for Precision Forming (CPF) / © Copyright Center for Precision Forming (CPF). All Rights Reserved. Introduction to Hot Stamping and Trends

2 Center for Precision Forming - CPF 2 CPF is supported by NSF and 16 member companies, interested in metal forming.

3 CPF – Current Projects Material Characterization Friction / Lubrication Process Simulation / Forming Al & AHSS Die Wear in Forming AHSS Edge Quality in Blanking / Shearing Hot Stamping of UHSS Servo Drive Presses and Hydraulic Cushions 3

4 Sponsors & Partners of Hot Stamping Research 4

5 5 Crashworthiness Crumple Zone Passenger Zone Images from: media.Daimler.com

6 6 Crashworthiness Passenger Zone Crumple Zone Absorbing Energy High Strength + Elongation Intrusion Resistance Ultra High Strength Ref: Hilfrich A-pillars B-pillars Roof rail Door beams

7 Summary of Hot Stamping 7

8 8

9 Indirect Process: Direct Process: 9

10 10 Hot Stamping - Trends Mass % of hot stamped steel in BIW Volvo V40 20% Volvo XC90 7% Volvo XC90 44% VW Passat 19% Audi A3 26% VW Golf VII 28% 1984 SAAB 9000 Ref: Lund 2009, Holzkamp 2011, Lindh 2011, Bielz 2012, Mattsson 2012, VW Media Services.

11 11 Hot Stamping - Trends Parts per year (in millions) 3 million per year (1987) 8 million per year (1997) 95 million per year (2007) 450 million per year (2013) 210+ lines around the world +55 planned 4 Parts/ Vehicle 6 Parts/ Vehicle 8-10 Parts/ Vehicle >20 Parts/ Vehicle Ref: Oldenburg 2010, Hund 2011.

12 Hot Stamping - Trends 12 Passenger Zone Deformation Zone (b) Side view aftercrash (a) Front view before crash Ref: Macek 2006, Image from: IIHS.

13 Hot Stamping - Trends 13 Tailor Rolled BlanksTailored Hot Stamping Tailor Welded Blanks Ref: Rehse 2006, Hilfrich 2008, Lee 2012, Images from: IIHS, VW Media Services.

14 Hot Stamping - Trends 14 Tailored Heating (Austenitizing) Tailored QuenchingPost Tempering Ref: Breidenbach 2009, Hedegärd 2011, Süß 2011, Steinhoff Image from: IIHS.

15 Hot Stamping - Trends 15

16 16 Finite Element Simulation of Hot Stamping Our simulations aim to predict the final properties of hot stamped components: 1)Presence of defects: cracks, wrinkles or local necking, 2)Hardness distribution (both in uniform and in tailored parts), 3)Cooling channel analysis, 4)Distortion of the final part.

17 17 Microstructure Evolution Mechanical Field Thermal Field Fluid Mechanics Heat transfer to the coolant medium. - Thermal material properties, - Latent heat due to phase transformation. Microstructure depends on temperature. - Mechanical material properties, - Volume change due to phase transformation. Phase transformation depends on stress and strain. Heat generation due to plastic deformation. Thermal expansion. Ref: Åkerström 2006, Porzner Finite Element Simulation of Hot Stamping

18 18 Only needed in tailored parts Finite Element Simulation of Hot Stamping

19 Part stamped at the participating company 19 Predicting Defects Crack prediction in a Side Member Reinforcement Colors other than gray: Thinning >20%.

20 20 Predicting Defects

21 21 Predicting Defects Crack / wrinkle prediction in a tailored part

22 22 Hardness Distribution 4 seconds die quenching 10 seconds die quenching Die Quenching Optimization

23 Hardness Distribution Air Quenching Stage Ref: Shapiro

24 24 Hardness Distribution Results Hardened zone: 485 – 515 HV 1500 – 1590 MPa (~220 – 230 ksi) Soft zone: 310 – 330 HV 920 – 1020 MPa (~135 – 150 ksi) Literature: [George 2011], 400°C dies = MPa [Feuser 2011], 450°C dies = ~850 MPa

25 25 Cooling Channel Analysis 1.3 mm 22MnB5 roof rail Mass produced for a European car. Cooling channel performance

26 26 Cooling Channel Analysis Cooling channel performance – tailored part 1.2 mm 22MnB5 B-pillar

27 27 Distortion Analysis Ref: Porzner Ongoing work: Distortion in Tailored Parts

28 28 Summary and Conclusions Several case studies were used to develop, calibrate and validate material models, conversion factors and methods to predict: 1)Defects (cracks, wrinkles, local necks), 2)Vickers hardness, yield and ultimate tensile strengths, 3)Cooling channel / heating cartridge performance, 4)Distortion in a non-uniform part.

29 What is next? 29 Ref: Lanzerath 2011, Vietoris 2011, Ferkel 2012, Lee High Strength (USIBOR 2000, MBW1900, HPF 2000) 22MnB5 (USIBOR 1500, MBW1500, HPF1470) High Elongation (DUCTIBOR 500, MBW500) 1) New materials with even higher strength: More lightweight potential and increased productivity. 2) New coatings: better corrosion properties and friction conditions. 3) New heating, forming and quenching methods to improve productivity. Competition: DP, TRIP, TWIP, and 3gAHS Steels with high YS and UTS.

30 Deliverables / Hot Stamping As of September 2013: - 15 CPF Reports (Literature review and FE simulations), (5 in the last 6 months) [confidential to members], - 6 Stamping Journal R&D Updates (+1 more in progress), - 6 Conference Proceedings (+1 more submitted), - 1 Book Chapter in Sheet Metal Forming: Vol 2: Processes and Applications, (see next slide), - And a new Hot Stamping book in progress! 30

31 Questions / Comments? For more information, please contact: Dr. Eren Billur Ph Dr. Taylan Altan Center for Precision Forming –CPF (www.cpforming.org) 339 Baker Systems,1971 Neil Ave, Columbus, OH Non-proprietary information can be found at web sites: References can be sent upon request. 31


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