research for industry and government stamping · pdf filetribology (friction, tool wear)
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ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
ERC/NSM Activities
Stamping Hydroforming MachiningForging
Research for Industry and Government
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
ERC/NSM 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
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
1. Materials/Flow Stress and
Formability - Hydraulic Tube Bulge Test -
Hydraulic Bulge Test Equipment
•Determination of Flow Stress of Tubes for Hydroforming
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
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
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
P = 11.9 MPa
17 % Exp.
t = 0.486 mm
P = 14.3 MPa
28 % Exp.
t = 0.427 mm
P = 13.1 MPa
23 % Exp.
t = 0.448 mm
P = 16.5 MPa
40 % Exp.
t = 0.379 mm
P = 18.3 MPa
55 % Exp.
t = 0.320 mm
Diameter : 2.250” (57.15mm)
Thickness : 0.024” (0.60mm)
1. Materials/Formability of
304 Stainless Steel
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
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
2. Tribology
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
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.
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
Load Cell
Pressure
Transducer
Rod
Tube
Die-Insert
pi
Fa Fa
Ff
pi
Fa Fa
Ff
saxsax
FFR FFRFFR FFR
2. Tribology/Tooling for Lubrication
Test - Guiding Zone -
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
2. Tribology/Lubricant Evaluation- Test Results for LCS 1008 -
Internal Pressure p = 600 bars Sliding Velocity v = 65 mm/s (2.5 in./s)
0.000
0.010
0.020
0.030
0.040
0.050
0.060
0 20 40 60 80 100 120
Sliding Length (mm)
Co
eff
icie
nt
of
Fri
cti
on
m
Lub E
Lub D
Lub A
Lub B
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
2. Tribology/Limiting Dome Height Test - Transition Zone -
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
Initial blank
(Circular blank with hole at the
center)
Stretched blank
(Change in hole diameter)
Punch
Die
Clamping ring
2. Tribology/Modified LDH test
- Transition Zone -
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
2. Tribology/Tooling for Lubrication
Test - Expansion Zone -
Pear Shaped Expansion Test
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
2. Tribology/
Pear-Shaped Expansion Test
Lubricant Performance as a function of Protrusion Height
68
68.5
69
69.5
70
70.5
71
71.5
72
72.5
Lub A Lub E Lub D Lub B No Lub
Lubricants
Pro
tru
sio
n h
eig
ht
PH
[m
m]
Specimen material SS304
Increasing interface friction
PH
Increasing interface friction
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
2. Tribology/Twist Compression
Test (TCT) - Principles of Operation -
Fr
T
*m
r
T
F
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
2. Tribology/TCT Samples
Before Test After Test
Material: AISI 1010 CR
Pressure: 500 bar
Sliding Velocity: 17 mm/s
Sliding Length: 160 mm
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
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
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
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
3. Process Development
and Modeling
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
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)
3. Process Development
and Modeling
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
3. Process Modeling /THF of T
Shape
Part Name: T fitting
Software: DEFORM3D
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
3. Process Modeling /THF of T
Shape
Part Name: T fitting
Software: DEFORM3D
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
Part Name: Exhaust Part
Software: PAM-STAMP
3. Process Modeling /THF of an
Exhaust Part
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
3. Process Modeling /THF of a
Cross Member
Part Name: Cross Member
Software: PAM-STAMP
Lower Die
Upper Die
Side Wall
Side
Wall
Tube (Workpiece)
Pre-forming Calibrating / Hydroforming
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
3. Process Modeling /THF of a
Cross Member
Part Name: Cross Member
Software: PAM-STAMP
Pre-forming
Pre-forming Calibrating / Hydroforming
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
3. Process Modeling /THF of a
Cross Member
Part Name: Cross Member
Software: PAM-STAMP
Pre-forming Calibrating / Hydroforming
Hydroforming
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
Part Name: Structural Part
Software: PAM-STAMP
3. Process Modeling /THF of a
Structural Part
Bending Calibrating / Hydroforming
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
Part Name: Structural Part
Software: PAM-STAMP
3. Process Modeling /THF of a
Structural Part
Bending Calibrating / Hydroforming
Bending
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
Part Name: Structural Part
Software: PAM-STAMP
3. Process Modeling /THF of a
Structural Part
Bending Calibrating / Hydroforming
Hydroforming
ERC
NSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.
3. Process Modeling /THF of a
Roof Frame Section
Part Name: Roof Frame
Software: LS-DYNA