D Metrology in Sheet Metal orming Process Chains Tata Slide 1 Steel Tushar Khandeparkar, Toni Chezan Process Optimization in Sheet Metal Forming through Forming Analysis with ARGUS January 25, 2017 GOM Workshop 3D Metrology in Sheet Metal Forming Processes
3D Metrology in Sheet Metal Forming Processes Tata Steel Slide 2 Agenda 1 Introduction 2 Technical Customer Support 3 Optical 4 Forming Measurement
3D Metrology in Sheet Metal Forming Processes Tata Steel Slide 3 Tata Steel Group A global network for demanding customers all over the world Scandinavia Western Europe North America Western Europe Western Africa CEE Turkey CIS India China Japan Hong Kong SE Asia Key Steel making operations Distribution and downstream assets Sales offices Latin America South Africa New Zealand
3D Metrology in Sheet Metal Forming Processes Tata Steel Slide 4 Tata Steel Research and Development Product Application Center Skills along the production process chain Forming Joining Mechanical product performance Surface technology Knowledge of materials internal structure and surface characteristics Familiarity with production process at customers
3D Metrology in Sheet Metal Forming Processes Tata Steel Slide 5 Materials Testing Using ARGUS and ARAMIS X die inspection Bulge test Tensile test with hole ARGUS ARAMIS Nakajima test Turkey tray test Hole expansion test
3D Metrology in Sheet Metal Forming Processes Tata Steel Slide 6 Tata Steel Forming Limit Curve (FLC) Prediction of material failure important for determination of forming process reliability four important points with ARAMIS and following, mathematical determination of FLC, based on tensile test data
Tata Steel Slide Technical Customer Support Usage of Forming Analysis
3D Metrology in Sheet Metal Forming Processes Tata Steel Slide 8 Technical Customer Support Initial operation of tool and series production Determination of forming process reliability and process window as well as identification of critical areas Evaluation of numerical process simulation accuracy More reliable prediction for new designs Evaluation of weight and cost reduction options through value analysis (VA/VE) Responsibilities in press shop Coil or blank width Blank length Shape and position of blank in tool Part orientation regarding the direction of rolling Responsibilities in engineering functional requirements Increase of material quality and reduction of sheet metal thickness Reduction of material quality Integration of several parts Adaptation of manufacturing process Blank meshing
3D Metrology in Sheet Metal Forming Processes Tata Steel Slide 9 Design optimization In-Form Scanning (sheet metal/tool), e.g. using ATOS and export to CAD file Forming simulation of a virtual side panel Forming of side panel (incl. forming analysis with ARGUS) In-Form TM Optimization followed by FLD verification Development of new ideas Analysis of critical areas of virtual side panel
3D Metrology in Sheet Metal Forming Processes Tata Steel Slide 10 Forming Analysis with ARGUS Grid Forming FLD report Results 3D forming measurement ARGUS
3D Metrology in Sheet Metal Forming Processes Tata Steel Slide 11 Example Press Shop Support with ARGUS Part fractures forming process window analysis Regular blank holder force settings: Both corners are critical distance to FLC < approx. 5 % (left side 2-3 % better than right side) Increased process security, if material has a lower RP value The material flow detected on the left side of the part was higher than on the right side Left Right Left Right 1 % 0% FLC 5 % 2 % RP value RP value
3D Metrology in Sheet Metal Forming Processes Tata Steel Slide 12 Example Press Shop Support with ARGUS Part fractures forming process window analysis Reduced blank holder force settings: Enhanced process reliability. Left side 2-3 % better than right side On the right side of the part, higher material flow was detected No folds detected on the part sufficient blank holder force Left Right Left Right 4 % 3 % 7 % 5 % RP value RP value
3D Metrology in Sheet Metal Forming Processes Tata Steel Slide 13 Example Press Shop Support with ARGUS Geometry comparison with ARGUS grid The point cloud of the ARGUS grid was exported The left half was mirrored and projected onto the right half The color plot shows the difference between left and right side Detection of differences in drawbeds geometry Right side A B A Left side B Section B-B mm
3D Metrology in Sheet Metal Forming Processes Tata Steel Slide 14 Usage of ARGUS XL and SVIEW Forming analysis of large sheet metal components Combination of several areas in one project with ARGUS XL Inspection of the impact of one area on the other area FLD for all three ARGUS projects ARGUS Project 1 ARGUS Project 2 ARGUS Project 3 Distance to FLC
3D Metrology in Sheet Metal Forming Processes Tata Steel Slide 15 Local Forming Analysis Point and full-field analysis and comparison to FLC Impact of material flow of one area on the other B A E F A FLD for labeled areas C FLD for labeled areas
Tata Steel Slide Sheet Metal Thickness
3D Metrology in Sheet Metal Forming Processes Tata Steel Slide 17 Utilization of ATOS 3D Scanner Photogrammetry ATOS 1. Geometry is measured from both sides + 2. Both geometries are oriented in one coordinate system
3D Metrology in Sheet Metal Forming Processes Tata Steel Slide 18 Utilization of ATOS Detailed visualization of geometry and material thickness distribution in molded sheet metal part No grid needed no change in friction properties
Tata Steel Slide Forming Measurement
3D Metrology in Sheet Metal Forming Processes Tata Steel Slide 20 of Forming Measurement Sheet metal forming Sheet metal forming can be affected by material properties (mechanical properties, material thickness etc.) and process parameters (sort and amount of lubricant, drawing speed etc.) The forming is measured on the surface and calculated in the mid-plane hereinafter. The part geometry (particularly small radii) can have an impact on this computation The applied amount of lubricant in the etched area can influence the resulting forming Increasing the drawing speed can lead to a reduced friction force. Therefore, the drawing speed can have an impact on the forming
3D Metrology in Sheet Metal Forming Processes Tata Steel Slide 21 Summary Forming analysis with ARGUS ARGUS offers a high-end solution for forming measurement at the customer s site (press shop support) The accuracy of numerical process simulation can be validated in SVIEW using a ARGUS forming measurement more reliable prediction for new designs Considering all possible impact parameters, the user can guarantee the reliability of the results and benefit from numerous possibilities
Thank you very much. Tata Steel Slide