Forming Challenges for Mass Optimization

Transcription

1 Forming Challenges for Mass Optimization Shiloh Industries, Inc. March 21, 2013 Cliff Hoschouer, Steve Fetsko, Jim Evangelista, Mike Telenko Shiloh Engineering and Technology Shiloh Industries, Inc. Data classification: Internal 3/25/2013

2 Geographic Locations Albany-Chicago Company Aluminum Die Casting Canton Manufacturing; Sales &Technical Center, MI, USA Engineering, Blanking, EWB, Stamping, Modular Assembly Medina Blanking OH, USA Engineering, Blanking, EWB, Laser Cutting Bowling Green Manufacturing KY, USA Heavy Gauge Blanking, Stamping Liverpool Coil Processing OH, USA Coil processing, Stamping, Modular Assembly, AcroStikTM Dickson Manufacturing TN, USA Ohio Welded Blank OH, USA Complex Stamping, Modular Assembly Blanking, EWB, AcroStikTM Shiloh de Mexico Ramos Arizpe, Mexico Jefferson Manufacturing GA, USA Wellington Manufacturing OH, USA Blanking, EWB, Stamping, Modular Assembly Blanking, EWB, Stamping Complex Stamping, Modular Assembly

3 Our Customers

4 Product Applications 4

5 Outline Current Forming Challenges Advanced High Strength Steel (Trip 780) Engineered Welded Blanks What are the future forming challenges? Aluminum Forming Including welded blanks 3/25/2013 5

6 Current Challenges Advanced High Strength Steel Challenges for forming Material variability To Within Material edge failures Possible forming solutions 6

7 Advanced High Strength Steel Material Variability Within Coil: Trip 780 Master coil Left hand part failures Right hand part failures Slit line Left Side Coil Right Side Coil 2 out Progressive Die Width of master coil 3/25/2013 7

8 Advanced High Strength Steel Material Variability: Trip 780 Hole Expansion test to help determine edge cracking 22.5% Strain = 10.6% thinning Target: 14.7% Strain = 7% thinning 12.2% Strain = 5.7% thinning 8

9 Advanced High Strength Steels Edge Cracking Issues 780 trip Steel Standard Blanking Zone B Zone A 9

10 Advanced High Strength Steels Possible Solution for Zone A Purple (current blank) Blue (run 3 blank) Green (run 3A blank) 10

11 Advanced High Strength Steel Possible Solution for Zone B Partially filled in zone B 11

12 Advanced High Strength Steel Possible Solution for Zone B Small rib added to lower tooling Patent Pending 12

13 Advanced High Strength Steel Possible Solution for Zone A Small rib Zone A in blank Patent Pending 13

14 Advanced High Strength Steel Summary Key is to relieve stress on the edge of the part Adding material to the outside of the blank Placing features in the die/blank to relieve stress on the outside edge 14

15 Current Challenges Engineered Welded Blanks Challenges Lack of curvilinear knowledge in the industry (perceived costs and benefits not understood) Adjusting joining line according to product requirement for mass optimization Adjusting joining line for improved formability 15

16 Engineered Welded Blanks (EWB) Base Design Vehicle Mass Optimization Case Study for HEV Door Inner Curvilinear Weld Option Blank Gauge in mm Mass in kg Thick Blue Thin Green Total Kg /Door Mass Savings Blank Gauge in mm Mass in kg Thick Pink Thin Brown Total

17 Engineered Welded Blanks (EWB) Balance - Formability & Mass Savings 17

18 Engineered Weld Blanks Summary Curvilinear blanks typical have NOcost penalty compared to a linear welded blank Welded Blanks can improve formability while reducing on vehicle mass Reduce cost of introducing more expensive light weight materials 18

19 Multi-piece Aluminum Monolithic Aluminum Aluminum Welded Blanks 3/25/

20 Aluminum Forming Challenges Lack of experience and difficulty in finding specific aluminum data Reduced formability due to material properties R-values < 1 Work hardening Possible forming solutions 3/25/

21 How is aluminum forming different? Over 90% thinning 2 inches from bottom 3/25/

22 What needs to change? The Dies? Or The Product? BOTH 3/25/

23 Example of Aluminum vs. Steel 2mm 1mm 2mm Prototype 3 piece welded blank fender inner. Die was developed for steel utilizing linear laser welded blanks. Die is now available for Aluminum development trials. Completed modification of die for Aluminum based on formability studies. Fabrication of Aluminum parts: 3/25/

24 AL in original steel tool Thinning Weld line locations 34.3% 82.9% 31.1% 31.6% Thinning : Target <? Max. (82.9%) 3/25/

25 Changes to the die are needed Area removed from die Steel Die Aluminum Die 3/25/

26 Aluminum Forming Simulation 3/25/

27 Aluminum Material Joining Laser Welding Adjust parameters to develop weld characteristics: Filler wire vs. autogenous Shield gas vs. no shield gas Root and crown shielding Successful ASTM E 8 tensile test Formability trials in process Friction Stir Welding Solid state welding process, no material melting, retains original material properties Slower process than laser welding Extremely high fixturing and processing forces require Successful AWS D1.2 tensile test Successful AWS B4.0 bend test Robotic end effector FSW head Potentially different FSW tooling for every material grade and thickness combination 3/25/

28 Aluminum Forming Simulation Weld line locations Thinning : Target <? Max. (26.0%) 3/25/

29 EWB aluminum Fender 2mm 2mm 3/25/

30 Laser Weld forming of Aluminum 3/25/

31 Summary Advanced High strength steels will continue to be challenging for the next 5 years Curvilinear Welded Blanks can provide needed on vehicle mass reduction now and in the future Aluminum Is Coming!! 31

32 Cliff Hoschouer Engineering Analyst Shiloh Industries Steve Fetsko Engineering Analyst Shiloh Industries Jim Evangelista Director Technology & Business Development Shiloh Industries