ERC/NSM Activities. Research for Industry and Government

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1 / Activities Research for Industry and Government Stamping Hydroforming Machining Forging

2 / Activities in Tube Hydroforming 1. Materials Determination of material flow stress data for tubular materials with Hydraulic Bulge Test at room temperature Determination of material flow stress data at elevated temperatures 2. Tribology (Friction, Tool Wear) Improvement of Tribological Conditions in Tube Hydroforming by Using Environmentally Friendly Lubricant Systems and Textured Tubes Viability of the Twist Compression Test for Screening Tube Hydroforming Lubricants 3. Process Modeling / Tool and Process Design Simulation of T shape hydroforming Simulation of Y shape hydroforming Simulation of hydroforming an exhaust pipe component Simulation of hydroforming a cross member Simulation of hydroforming a structural member Simulation of hydroforming a roof frame section

3 1. Materials/Flow Stress and Formability - Hydraulic Tube Bulge Test - Hydraulic Bulge Test Equipment Determination of Flow Stress of Tubes for Hydroforming

4 1. Materials/Flow Stress and Formability - Hydraulic Tube Bulge Test - Potentiometer with Thermocouple Die and Die Holder Punch with heating elements Hydraulic Cylinder Insulator (hard wood) Flow stress and material formability at elevated temperatures

5 1. Materials/Formability of 304 Stainless Steel Diameter Thickness : (57.15mm) : (0.60mm) P = 11.9 MPa P = 13.1 MPa P = 14.3 MPa P = 16.5 MPa P = 18.3 MPa 17 % Exp. 23 % Exp. 28 % Exp. 40 % Exp. 55 % Exp. t = mm t = mm t = mm t = mm t = mm

6 2. Tribology Main Research Activities: Improvement of Tribological Conditions in Tube Hydroforming by Using Environmentally Friendly Lubricant Systems and Textured Tubes Viability of the Twist Compression Test for Screening Tube Hydroforming Lubricants

7 2. Tribology/Friction and Lubrication Friction conditions at different contact locations Due to different tribological conditions at the Guiding, Transition and Expansion zones, different lubrication tests are needed.

8 2. Tribology/Tooling for Lubrication Test - Guiding Zone - Load Cell Pressure Transducer Rod Tube F a Fa s ax Die-Insert FFR pi F f F FR

9 2. Tribology/Lubricant Evaluation - Test Results for LCS Coefficient of Friction m Lub E Lub D Lub A Lub B Sliding Length (mm) Internal Pressure p = 600 bars Sliding Velocity v = 65 mm/s (2.5 in./s)

10 2. Tribology/Limiting Dome Height Test - Transition Zone -

11 2. Tribology/Modified LDH test - Transition Zone - Punch Clamping ring Die Initial blank (Circular blank with hole at the center) Stretched blank (Change in hole diameter)

12 2. Tribology/Tooling for Lubrication Test - Expansion Zone - Pear Shaped Expansion Test

13 Protrusion height PH [mm] 2. Tribology/ Pear-Shaped Expansion Test Specimen material SS PH Lub A Lub E Lub D Lub B No Lub Lubricants Increasing interface friction Increasing interface friction Lubricant Performance as a function of Protrusion Height

14 2. Tribology/Twist Compression Test (TCT) - Principles of Operation - F r m r T * F T

15 2. Tribology/TCT Samples Before Test After Test Material: AISI 1010 CR Pressure: 500 bar Sliding Velocity: 17 mm/s Sliding Length: 160 mm

16 3. Process Development and Modeling Process Development Forming Limit Diagrams Process limits and control Prediction of process parameters Process simulation using FEA Innovative THF Warm THF for processing Mg alloys Engineered tubes with varying wall thickness in circumferential and longitudinal directions

17 3. Process Development and Modeling Process Development Considerations Material characteristics Workpiece geometry Interface friction coefficient / lubrication Process parameters (loading paths for axial feed, internal pressure and counter punch application) Die design considerations Press capacity and characteristics

18 3. Process Development and Modeling Process Modeling THF of fitting components T- Shape (DEFORM 3D) Y- Shape (PAM-STAMP) THF of medium size automotive components Exhaust Pipe (PAM-STAMP) THF of large size automotive components Cross member (PAM-STAMP) Structural Part (PAM-STAMP) Roof Frame (LS-DYNA)

19 3. Process Modeling /THF of T Shape Part Name: T fitting Software: DEFORM3D

20 3. Process Modeling /THF of T Shape Part Name: T fitting Software: DEFORM3D

21 3. Process Modeling /THF of an Exhaust Part Part Name: Exhaust Part Software: PAM-STAMP

22 3. Process Modeling /THF of a Cross Member Tube (Workpiece) Upper Die Side Wall Part Name: Cross Member Software: PAM-STAMP Lower Die Side Wall Pre-forming Calibrating / Hydroforming

23 3. Process Modeling /THF of a Cross Member Pre-forming Part Name: Cross Member Software: PAM-STAMP Pre-forming Calibrating / Hydroforming

24 3. Process Modeling /THF of a Cross Member Hydroforming Part Name: Cross Member Software: PAM-STAMP Pre-forming Calibrating / Hydroforming

25 3. Process Modeling /THF of a Structural Part Part Name: Structural Part Software: PAM-STAMP Bending Calibrating / Hydroforming

26 3. Process Modeling /THF of a Structural Part Bending Part Name: Structural Part Software: PAM-STAMP Bending Calibrating / Hydroforming

27 3. Process Modeling /THF of a Structural Part Hydroforming Part Name: Structural Part Software: PAM-STAMP Bending Calibrating / Hydroforming

28 3. Process Modeling /THF of a Roof Frame Section Part Name: Roof Frame Software: LS-DYNA

29 3. Process Modeling /THF of a Roof Frame Section Part Name: Roof Frame Software: LS-DYNA

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