CPF Presentation

7/27/2019 CPF Presentation

1/13

CPF

Center for Precision Forming(www.cpforming.org)

Taylan Altan, Director (email: [email protected])

A short Review

July, 2011


2/13

CPF

The Ohio State University (OSU) and have established theIndustry/University Cooperative Research Center (I/UCRC) on

Precision Forming (CPF) focusing on research needs of metal

forming industry.

Funding is provided by National Science Foundation (NSF) andmember companies.

CPF (www.cpforming.org) benefits from research conducted at

Engineering Research Center for Net Shape Manufacturing

(ERC/NSM www.ercnsm.org).

Introduction

2
http://www.cpforming.org/http://www.cpforming.org/http://www.cpforming.org/http://www.cpforming.org/http://www.cpforming.org/http://www.cpforming.org/


3/13

CPFObjectives

Improve existing metal forming processes/products and develop new

innovative processes, tooling and equipment.

Conduct projects in close collaboration with industry and transfer the

results to the member companies.

Train and educate engineers in the fundamentals and practice of metal

forming science and technology.

3


4/13

CPFCurrent Members Aida- America Corp.

Boeing

EWI

Honda

ESI North America

General Motors Corp.

Interlaken Technology Corp.

POSCO (Korea)

IM Steel

Scientific Forming Technologies (SFTC) Corp.

IMRA America

Metalsa

JCI

Thixomat

Tyco

Labein

Cincinatti, Inc 4


5/13

CPF

CPF 1.1: Elevated temperature stamping and hydroforming of Al, Mg and

Stainless Steel

Objective:

Develop guidelines for elevated temperature sheet forming (process optimization,

lubricant evaluation and Finite Element Modeling)

Warm deep drawing (in cooperation with AIDA Engineering, Ltd.)

Current Projects

5


6/13

CPF

CPF 1.4: Investigation of springback in forming Advanced/High

Strength Steel (A/HSS)Objectives:

Determine the variation ofYoungs Modulus with deformation /strain

Predict and reduce springback in stamping A/HSS

Planned experiments (Tool concept)

1. Straight flanging

2. Stretch flanging

3. Shrink flanging4. Straight hat shape drawing and stretching

5. Curved hat shape drawing and stretching

Current Projects

6


7/13

CPF

CPF- 2.1: Determination of room temperature properties of Al and steel

sheet materials under biaxial conditions

Develop a standardized tool design and procedure to determine flow stress,

anisotropy and formability under biaxial deformation

Objective:

Sheet bulge test

(Viscous Pressure Forming VPF)

Current Projects

7


8/13

CPF

Hole

Modified Limiting Dome Height

(MLDH) Test

Formed sample

(OD = 14in, t0 = 0.034in)

CPF- 2.2: Determination of flow stress of Al and Mg sheet materials at

elevated temperaturesObjective:

Determine flow stress of sheet materials at elevated temperatures for the warm

forming process.

Inverse Analysis Technique

Current Projects

8


9/13

CPF

CPF- 2.3: Investigation of tribological conditions in forming uncoated

and galvanized Advanced/Ultra High Strength Steels (A/UHSS)

Determine the effect of process parameters (interface temperature, pressure and

relative sliding speed) on galling / reduce galling

Objective:

Twist compression Test (TCT)

Current Projects

T

P

A

rm

Testing materials: DP 600 Bare with Lub A Testing conditions: P = 170 MPa & N= 8.9 RPM

Tool surface

Galling

Micrograph of galled surface

9( in coo peration with IRMCO)


10/13

CPF

CPF - 4.1: Multi Point Control (MPC) die cushion and blank holder

technology in stampingObjective:

Develop an automated system to optimize the Blank Holder Force for robust

stamping

Proposed system for robust stamping using MPC

Current Projects

Die

Blank holder /

Binder

Individual hydraulic

cylinders for each

cushion pin

(Source: Mller Weingarten)

Location of cushion pins/

cylinders in the die

(cont inue)

10


11/13

CPF

Parts formed with OSU software by USCAR (try-out reduced from 3 days to 3 hours)

Current Projects

Al 6111-t4 (t = 1 mm) BH210 (t = 0.81 mm) DP500 (t = 0.78 mm)

CPF - 4.1: Multi Point Control (MPC) die cushion and blank holder

technology in stamping (continue)

Sample parts [GM lift gate inner panel] with different materials and sheet thickness was formed in

the same die by simply adjusting the BHF.

11


12/13

CPF

CPF- 4.2: Applications of Tube Hydroforming (THF) Technologies

Objective:

Utilize past R&D experience at OSU to assist interested companies in

introducing and/or improving the hydroforming technology

Current Projects

12General concept of Tube Hydroforming Process(Hydroforming of the T-shape part)

A.

B.

C.

D.

[Leitloff , 1997 ]


13/13

CPF

New tasks under consideration

Cold and Warm Hydroforming of Al and Mg alloys

Simulation of Hot Stamping of Boron Steels

Precision /Flashless Forging of automotive components (for example

tie rods, pinion gears and bevel gears)

Prediction and reduction of residual stresses in machining and burnishing

(advanced FE analysis)

Micro-stamping for electronic applications (lead frames, CD drive

components, etc.)

Center for Precision Forming(CP-Forming-www.cpforming.org)

13

Documents

CPF Presentation