Press hardening from a global perspective. Dr. Martin Skrikerud Vice Chief Technical Officer

Transcription

1 Press hardening from a global perspective Dr. Martin Skrikerud Vice Chief Technical Officer

2 AP&T WORLD WIDE SALES AND SERVICE China Czech Republic Denmark Germany Japan Poland Slovakia Sweden United Kingdom USA AGENTS Belgium Brazil CIS Finland Italy Mexico Netherlands Norway South Korea Turkey PRODUCTION Blidsberg, Sweden Brescia, Italy Tranemo, Sweden HEADQUARTERS Tranemo, Sweden

3 ONE RESPONSIBLE PARTNER Automation Operators Interface Presses Tool Handling Systems Tools Technology Integration Customer Service Project Management Documentation Production Lines Competence in-house >> Modular-based systems >> Follow our customers globally Personal contacts at all levels >> Market leader in defined niches

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5 Press Hardening History Mid19-century the first hot rolled and cold rolled boron steel was developed by Norrbottens Jernverk, Luleå (Today SSAB) The press hardening process (HotStamping) was developed by Norrbottens Jernverk First R&D Project Volvo Truck and Plannja HardTech Saab Automobile AB became the first vehicle manufacturer to use hardened boron steel component (Side impact beam) 1991 First bumper beam (Ford)

6 The process

7 Boron Alloyed Steel: 22MnB5 Controlled quenching within the tool TTT-Curve for 22MnB5 Ferrite Heating of single blanks Martensite Perlite Bainite Source: Naderi et al. [2007] Delivery Condition* Perlite/Ferrite * Source: ArcelorMittal Final State* Martensite Source: TU Graz 7

8 Press Hardening Why? High strength Increase safety Reduce weight No sprinback Products: Side impact beams Front and rear bumpers Floor Tunnels B Pillars Chassis components

9 Press hardening sample geometries

10 Door ring Tailor Welded blank 0,9-1,8mm Usibor, Ductibor Part development tailored properties

11 Part development soft zones

12 Example soft zone die section Heating elements Isolation plates

13 MARKET TRENDS

14 CO2 Emission and Targets

15 CO 2 Emission and Targets potential Regulation for fleet Europe CO2 emission potential penalty McKinsey 01/2012

16 Reduced Weight Material Mix Today Mainly conventional steel (49%) Mainly Body in White Mainly Automotive Our Materials Today Tomorrow Mainly Steel, but UHSS + Steel (49%) plus Aluminum (13%) Materials 2020Plus UHSS 15% Magn. 5% Others 1 19% Magn. 5% Plastics 10% Comp. 3% Others 1 20% Alu 9% Alu 13% Steel 52% UHSS 37% Steel 12%

17 Safety demands change and get tougher

18 1 Increased components XC60-11% 50 % of BIW weight 40 ~40% 30 V40-20% V XC V XC S V Upper limit Upper limit - 40% The new SPA-platform will have about 40% boron steel parts

19 Cold formed Vs. Hot Formed, Study by FIAT B-PILLAR CPL MOD. 199 = + B-PILLAR CPL MOD. 312 patchwork

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21 Usage and future needs of Usibor (in addition, there is uncoated and Zn-coated material) Source: Arcelor Mittal

22 TOOLS FOR PRESS HARDENING

23 Cooling Channel Development Outlet Fig. A Inlet Cooling channels machined through the die sections. Better flow and easier to control the pressure drop. Technical figures Working pressure approx.7,5 Bar Pressure drop, approx. 1,5 Bar Flow approx. 150 liter / min / cavity

24 Die steels for different needs Material QRO 90 Divar (H 13 improved) Impax (P20 modified) Treatment PVD coating plasma nitrating Die parts in sections maintenance manufacturing

25 Customer case Panel Dash study

26 Customer case Panel Dash study Challenges Cracks Panel Dash part Wrinkles

27 Customer case Panel Dash study Panel Dash evaluation Due to friction in the die the parts crack Crack due to friction small cracks and wrinkles

28 Solution Surface coating Die clearance Blank shape Customer case Panel Dash study

29 Customer case Panel Dash study Wrinkles

30 Customer case Panel Dash study Solution Added grooves Blank shape Thickening 14 %

31 Sample panel dash: Cooling simulation of the dies 3D tools with cooling channels Tool temperature at the end of quenching

32 Production panel dash

33 Process optimization Cooling cycle in die s reduced to 4-8 s Die material Increased lifetime and better cooling ratios Handling parts From robot to linear systems Nr. of parts in die 2 to 4 to 6 to 8 / stroke Maintenance cost Multi layer furnace Space savings Possible to use existing buildings -50% space needed Solution Provider From press supplier to provider of production systems

34 Reference samples within Automotive Volvo Cars VW FIAT Tier 1 USA

35 Volvo Cars Ongoing Project 2 press hardening lines 9 sets of dies Cooling system 6 Lasers Training of personnel Extensive know-how transfer

36 FIAT Scope of Supply 5 complete press hardening lines 4 set of press hardening dies Development of Fiat hot forming tooling standards Training of operators and maintenance personnel 1 year of production support Turn Key supply 4 years of successful production

37 VW Scope of Supply 3 press hardening lines Training of operators and maintenance personnel ½ year of production support Turn key supply

38 Scope of Supply 2 press hardening lines 10 set s of dies Engineering support Training of operators and maintenance personnel 1 year of production support Turn key supply Tier 1 Supplier USA

39 AP&T Today Supply WW supply of 70+ complete hot forming lines WW supply of 60+ hot forming dies Developments and Try-out New production facilities New try out center Dies Materials Tailored properties Furnaces Laser

40 Thank you for your attention!