Advanced Steel Manufacturing and Stamping

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Presentation transcript:

Advanced Steel Manufacturing and Stamping Mike Smith BoronExtrication.com

Module Overview Hot stamping advanced steels What are tailored blanks? Where are tailored blanks used?

Hot Stamping

Hot Forming of a B-pillar Hot forming processes have recently become important for the automotive industry to meet specific requirements regarding a higher level of crash safety and a reduction of overall weight. Many automotive manufacturers use these processes to produce body structure components such as A and B-pillars, tunnels, front and rear bumper beams, door sills, door beams, side-rail parts, roof rails and roof frames. These components have the highest requirements regarding strength. The use of high strength steels in conventional stamping processes is difficult due to their reduced formability and strong tendency to springback. Hot forming technology can be used in order to overcome these limitations. Components are stamped in the soft stage at elevated temperatures and quenched after forming to achieve a martensitic structure resulting in a very high strength of 1500 MPa. Hot forming is a temperature and time dependent process and therefore its simulation is obviously more complex compared to conventional stamping processes. AutoFormplus R1 has been enhanced to include thermo-mechanical processes, making it possible to simulate hot forming.

Hot Stamping of Boron Steel

Tailored Blank A tailored blank is a sheet of steel that combines several grades and / or various thicknesses and / or different coatings, the different parts being laser welded together, in order to place the best material at the best place in the right thickness for a real “tailor-made” solution for the customer after stamping.

Vehicle Applications 1. Rear Rails 2. Roof Reinforcement 3. B-Pillar 4. A-Pillar 5. Shock Tower 6. Tailgate 7. Cross Member 8. Side Member 9. Wheel House 10. Engine cross member 11. Body side 12. Seat cross member 13. Bumper reinforcement 14. Front rail 15. Rear door 16. Floor panel 17. Front door 18. Tunnel reinforcement 19. Body side outer

Laser Welded Tailor Blank

Tailor-Rolled Blank

Audi A6 Body Structure

Audi

2011 Audi A8 The 2011 Audi A8 is a very uniquely built vehicle 2011 Audi A8 The 2011 Audi A8 is a very uniquely built vehicle. First off, the body is aluminum Audi Space Frame (ASF). Each part of the body structure of the Audi A8 is built depending on their tasks in the vehicle. The image below shows the lateral roof frame (light blue) is made with a single extruded section; its cross-section changes flexibly from the A-pillar to the C-pillar.