Advanced Stamping for High Strength Steels - Autosteel/media/Files/Autosteel/Great Designs in Steel... · Advanced Stamping for High Strength Steels ... Die Design for AHSS ... Progressive

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Advanced Stamping for High Strength Steels

J.P. McGuire

Chrysler Group LLC.

Advanced Stamping Manufacturing Engineering

© 2012 Chrysler Group LLC. All Rights Reserved.


Chrysler Material

Selection

Die Process

Full Cycle Simulation

Die Design for AHSS

Die Materials/Coatings

Die Engineering for AHSS Beyond 2014

Opportunities

Overview



2005 Grand Cherokee

29% HSS

2011 Grand Cherokee

50% HSS 60% HSS

Today

2011 Chrysler 300

Chrysler Group Material Selection

68% HSS


New Dodge Dart


47%

41%

4%

1% 4% 3%

2011 Grand Cherokee Material Usage

Mild Steel

HS Steel

AHS Steel

UHS Steel

Hot Stamp

Other

50% High

Strength

Steel

High Strength Steel: YS > 200 MPa

World Wide

Vehicle




38%

50%

4%

3% 1% 3%

2011 Chrysler 300 BIW Material Usage

Mild Steel

HS Steel

AHS Steel

Hot Stamp

Plastic

Other

World Wide

Vehicle

High Strength Steel: YS > 200 MPa © 2012 Chrysler Group LLC. All Rights Reserved.



37%

48%

10%

1% 1% 3%

2011 Dodge Charger BIW Material Usage

Mild Steel

HS Steel

AHS Steel

Hot

Stamp

Plastic

High Strength Steel: YS > 200 MPa

Largest TRIP590

Application in

Production




Dodge Dart

High Strength Steel:

YS > 200 MPa

68% High

Strength

Steel




Chrysler Material

Selection

Die Process


Die Design for AHSS


Die Engineering for

AHSS

Beyond 2014

Opportunities

Overview



Formations

P/O

Draw Trim Pierce/Restrike/Flange

Stricter Product Radii

Limits

New Methods to

Control Springback Stricter:

• Trim Angle

Standards

• Cutter Clearance

• Minimum Shear

Requirements

Stricter:

• Pierce hole angle

maximums

• Restrike only for

qualifying surface,

not “reforming”

On-going improvement working with product

engineering, die shop, and stamping plant

teams to develop best practice

Die Process for AHSS



Bead metal on flange

(utilization observation)

Large radii

Open walls

Gradual depth / LOL transition

Die Process for AHSS



DP 600

Springback &

compensate

Springback &

compensate

Springback &

compensate Springback &

compensate

Overcrown Surface Morph

Final detail

panel meets

GD&T tolerance



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DP 600




Example. AHSS Die Design Section

Increased Rib Thickness in Working

Areas

Enhanced Thrust Containment

Use of Separate Details in Working

Areas

In Some Cases Heavier Duty

Standard Components (i.e. punches,

nitro cylinders, cams, etc.).

Die Design for AHSS



Die Structure Analysis

Topology

Topography

Failure

Part Correlation

Die Design for AHSS



Dodge Dart AHSS Parts

Draw Die Trim Die

0.80 mm DP600 Floor Pans

Chrysler “A” Standard

(Base Materials and Sections)



Dodge Dart AHSS Parts

Progressive Die

1.6 mm DP980

Chrysler “D” Standard



Future AHSS Die Design

(Extreme Cases)

+ 2.0 mm DP 600, 780

+ 1.8 mm DP980

Sharp “V” part geometry

Sacrificial

Element

Future Die Design for AHSS



Coatings for Stamping Dies

18

Traditional Die Coatings • Chrome Plate (Class A Panels)

• Ion Nitride (Non AHSS Inner Panels)







This condition can cause:

-Poor formability (wrinkling)

-Poor dimensional properties

-Customer quality concerns

Class A surface quality

suffers, also increased

potential panel scrap

Bead wear premature,

causing panel run out







Coatings for Stamping Dies

New Coatings Required for AHSS Current Chrysler Standard • PVD – Physical Vapor Deposition • D2 Tool Steel • Stricter Metallurgical and Heat Treat

Requirements • Nitriding first with absence of white layer




Die Insert Coatings for AHSS

• T = 1300-1900 ºF

• 18 – 24 hours • Total Process: 5-7 days

• T = 400–950 °F

• 6-8 hours • Total Process: 3-5 Days

Cycle Time

Chemical Vapor Deposition Physical Vapor Deposition

Deposition




CVD-TiC PVD-CrN

0.08mm

Growth

No size

change

Die Insert Coatings for AHSS

White light scanning used to verify dimensional Change

A B

A B




Chrysler Material

Selection

Die Process


Die Design for AHSS


Die Engineering for AHSS Beyond 2014

Opportunities

Overview



This presentation contains proprietary, restricted information and not to be distributed without prior permission from Chrysler Group L.L.C.

Chrysler is currently studying Advanced Strength Steel with better

combination of Strength and Elongation.

Projects in Chrysler

Steel Technology to Reduce Material Property Variation

Future: New AHSS Steel Grades



Improved

Material

Property

Behavior Laws

In Depth Characterization of Both

Material & Die Behavior

Future: Ever Improving Material Models

Based on Production Data



New Preventative Maintenance

Requirements for AHSS

Small AHSS parts require higher

tonnage than previous

Training on new methods

Part temperature

Enhanced part sensing

Enhanced part guidelines for press

loading (improved simulation

accuracy)

Decoiling/leveling/front of line

Lower materials utilization ($$$)

Strong Case for Larger Tonnage

Presses (i.e. +3000 tons)

Future: Press/Facility Concerns for

Running AHSS



Questions?



North American

Light Vehicle Metallic Material Trends


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Advanced Stamping for High Strength Steels - Autosteel/media/Files/Autosteel/Great Designs in Steel... · Advanced Stamping for High Strength Steels ... Die Design for AHSS ... Progressive