Latest Improvements For Hot Forming Dies And Technologies

ToolingLatest improvements for hot formingdies and technologiesTechtank Conference 2017Olofström - SwedenJose Miguel Martin

ToolingSUMMARY1. Company introduction2. Multi properties solutions3. Cutting solutions for process improvements4. Hot forming technologies for other materials

ToolingCOMPANY INTRODUCTIONHotteknik: Business Unit forHot Forming Technology

ToolingCOMPANY INTRODUCTION

ToolingCOMPANY INTRODUCTIONTurnover97 M 13 M Workforce22%174 M AutomotiveSystemsEnergy1% 3%AutomotiveSystemsStamping Dies74%Stamping DiesTOTAL 284 M AVERAGE 1.600EnergyGroup Services

ToolingCOMPANY INTRODUCTIONHot forming:

ToolingCOMPANY INTRODUCTION

ToolingMULTI PROPERTIES SOLUTIONSMulti Properties parts solutions:Different engineering solutions to improve car crash performance.Optimizing mechanical properties and thickness of the part for saving weight andimproving crash performance.

ToolingMULTI PROPERTIES SOLUTIONSTailor quenched parts:Different microstructures(properties) can be achieved by controlling the coolingrate.Tailor quenched considerations: To have good contact in die due to material dilatation. To get good geometrical and mechanical properties part. Different tool steels tested. Study low thermal conductivity steels capability for tailor tempering. Different temperature ranges influence in final properties. Insulation solution between different areas. Final part geometry compensation (Springback).Technicallysupported by:

ToolingMULTI PROPERTIES SOLUTIONS* Simulation part dimensional measurements* Experimental part measurementsConclusions: Low conductivity materials have slight influence. The principal driver is the temperature of the steel block. Depending on final mechanical properties, tool temperature must be adjusted (Up to450ºC-500ºC for 220-250 HV) Tool expansion and springback must be compensated to achieve a good finalgeometrical accuracy Air gaps between blocks assure a good insulation between hot and cold areas Transition areas can be achieved between 30-40 mm.

ToolingMULTI PROPERTIES SOLUTIONSAlternative to compensate tool expansion (Tailor Tempering)1. Compensate the expansion of the heated steel blocks by analytical calculations orsimulations2. Milling heated steel blocks at production temperature.Technically supported by:Considerations for milling at production temperature: Cooled milling head Milling head sensorized Heated steel block sensorized Thermographic camera for thermal measuring Photogrammetry for geometrical measurement

ToolingCUTTING SOLUTIONS FOR PROCESS IMPROVEMENTSPre developed blank solution: Some areas are not laser cut after forming in order to reduce process cost. In areas where the trimming tolerances range allow it. Part process feasibility must allow work with pre developed solution.Pre developed blank shape considerations: Analysis of areas and tolerances with pre developed blank Accurate centering systems for repeatability of process. Several blank shape iterations. Adjustment of parameters in simulation to reduce blank shape iterations.Conclusions: Implemented solution in several produccion dies.Project: JLR

ToolingCUTTING SOLUTIONS FOR PROCESS IMPROVEMENTSHot Piercing solution: Some holes can be pierced in the forming operation to reduce cost. Implemented when part holes tolerances are reduced (location holes).Hot Piercing considerations: Die design (Cooling channels, Cutting tools and scrapping) Cutting process parameters (Clearance, Sharp edge, Cutting temperature ) Tool steel, heat treatment and coatings selection in active parts . Cutting effort and thermal hole dilatation compensation.Conclusions: Process cost can be reduced. Higher die manufacturing complexity. Lower cutting effort due to blank temperature.Technicallysupported by:

ToolingCUTTING SOLUTIONS FOR PROCESS IMPROVEMENTSHard Cutting solution: Some customers allow hard cutting process. Depending on project volume this process can be competitive.Hard Cutting considerations: Tool steel selection in active parts. Optimization cutting parameters (angles, clearances, sharp ) Tool Stiffness (clearance variation during cut process) Optimization Heat treatment and coatings. Sock absorber is needed (press or die)Project: FIAT

ToolingCUTTING SOLUTIONS FOR PROCESS IMPROVEMENTSConclusions: Tool stress can be calculated by simulation (FEM). Tool stress is dependent on punching clearance and cutting edge radius. The reaction force is calculated and this value must be used for a correct die design toprevent excessive tool displacement during the trim operation. Lower stress with optimal radius in the cutting edge. Process cost can be reduced. Higher dies investment

ToolingHOT FORMING TECHNOLOGIES FOR OTHER MATERIALSHS Aluminum and Magnesium Formability for these materials is poor at room temperature. Hot stamping processes can improve their formability.MATERIAL TESTED:AutomotiveAluminum:- AA 5083- AA 5754- AA 6082- AA 7075Magnesium:- AZ 31Technicallysupported by:

ToolingBatz font. 14 pts.Name Surnamefjdhjrbnv@batz.esTHANKS FOR YOUR ATTENTIONJose Miguel MartinHot Forming Key Account Managerjmmartin@batz.es

Systems Energy Stamping Dies 74% 22% 1% 3% Workforce Automotive Systems Stamping Dies Energy Group Services AVERAGE 1.600 . . 450ºC-500ºC for 220-250 HV) Tool expansion and springback must be compensated to achieve a good final . Some areas are not laser cut after