Introduction of EWI Forming Center

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1 Introduction of EWI Forming Center November 14, 2012 Ron Brown Director EWI Forming Center Office Hyunok Kim Technical Director EWI Forming Center Office: Page 1

2 Background President s Council of Advisors on Science and Technology JULY 2012 REPORT TO THE PRESIDENT ON CAPTURING DOMESTIC COMPETITIVE ADVANTAGE IN ADVANCED MANUFACTURING - 11 Top Cross-Cutting Technologies - pivotal in enabling U.S. manufacturing competitiveness Advanced Forming And Joining Technologies Page 2

3 Background Meeting the challenge thru collaboration EWI & OSU EWI Forming Center OSU Center For Precision Forming Page 3

4 Background Meeting the challenge thru collaboration EWI & OSU Unique in the western hemisphere EWI Forming Center Chairman - Dr. Taylan Altan Director Ron Brown Technical Director Dr. Hyunok Kim Page 4

5 Mission The mission of the center is to develop and advance innovative forming processes, tooling, and equipment; provide a technology and knowledge base to industry and government; and cooperate with the Ohio State University s Center for Precision Forming (OSU- CPF) to conduct fundamental research while training new engineers for the forming industry. Page 5

6 Strategy Establish Forming Center at EWI in cooperation with CPF-Center for Precision Forming of OSU Provide the knowledge base and infrastructure that exists at EWI and CPF (160 ton hydraulic press and tooling moved to EWI s laboratory) Establish cooperation with EWI and CPF staff and students to conduct projects for industry and government Utilize the strengths of both EWI and CPF in technology as well as business. Thus, while establishing and expanding the EWI-CPF continue to maintain CPF as the university link and fundamental research support. Continue to maintain and expand the close cooperation EWI and CPF have with companies interested in joining and forming technologies. Page 6

7 Structure of EWI Forming Center EWI-Joining R&D NSF/ other government EWI-Members Automotive Aerospace Energy EWI- Forming Center Activities-R&D in Sheet Forming Material characterizations/ formability Friction/lubrication Process simulation/quality/springback Fabrication Close cooperation CPF-OSU Industry, 15 companies (OEM/s, 1 ST Tier, software, tooling) Page 7

8 Activities of EWI Forming Center EWI-Forming Center and CPF-OSU Activities in R&D Effort EWI-Forming Center CPF-OSU From R&D to Production Basic R&D Proof of concept Lubrication application Page 8 Prototyping (pre-production) 8

industry-related non-proprietary results The center s inaugural event, a joint workshop

9 Next Step Create a Forming Center website Establish a group of friends of the Center Hold a semi-annual workshop (Next in March 2013) quarterly R&D updates Publish industry-related non-proprietary results The center s inaugural event, a joint workshop with OSU-CPF on Advance Sheet Metal Forming Technology at EWI headquarters on November 14, Page 9 9

Forming Equipment at EWI Type Slide Force Cushion Force Eject Force Slide Speed Slide Stroke Platen Size Test tooling Minster Tranemo DPA-160-10 160 metric tons (176.4 tons) 100 metric tons (110.

10 Forming Equipment at EWI Type Slide Force Cushion Force Eject Force Slide Speed Slide Stroke Platen Size Test tooling Minster Tranemo DPA metric tons (176.4 tons) 100 metric tons (110.3 tons) 15 metric tons (16.5 tons) 90 mm/s maximum (3.54-inch/s) 500 mm (19.68 inch) 1,000 x 1,000 mm (39.37 x inch) 7 different testing die sets available with the press 160-ton Minster Tranemo Press (Installed at EWI in Sept. 2012) Page 10

Forming Test Capabilities Formability tests: Tensile (up to 1000 F) test

Lubrication and Tool wear tests Strip galling test Deep drawing test

extrusion (DCE) test Biaxial Bulge Tested Sample (12-in x 12-in) Deep Drawn

depth) Stamping tests Bending and Flanging tests Rectangular deep drawing

11 Forming Test Capabilities Formability tests: Tensile (up to 1000 F) test Biaxial bulge test Billet upsetting and extrusion tests Friction, Lubrication and Tool wear tests Strip galling test Deep drawing test Limiting Dome Height (LDH) test Ironing test with heated dies Double cup extrusion (DCE) test Biaxial Bulge Tested Sample (12-in x 12-in) Deep Drawn Sample (6-in bottom dia. x 3.5-in. depth) Stamping tests Bending and Flanging tests Rectangular deep drawing test Springback tests Rectangular Drawn Sample (20-in. x 18-In. x 2-in. depth) DCE Tested Sample (1-in. dia. x 2.5-inch height) Page 11

Metal Forming (Forging) - Die stress and temperature distribution - Optimized die shape FE

12 Simulation Capabilities Process Simulations Sheet Metal Forming - Springback - Failures (necking and wrinkling) - Tool stress and wear - Tool design and process optimization Bulk Metal Forming (Forging) - Die stress and temperature distribution - Optimized die shape FE Modeling Tools - ABAQUS - DEFORM - LS-DYNA FEM of automotive part S-rail stamping simulation Page 12

13 Questions? Ron Brown Director EWI Forming Center Office Hyunok Kim Technical Director EWI Forming Center Office: Page 13

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Introduction to EWI Forming Center

Introduction to EWI Forming Center Oct. 21, 2013 Hyunok Kim, Ph.D. Technical Director EWI Forming Center 1 National Priority for Forming Technology Advanced Forming and Joining Technologies are recognized