gestamp-experience of vanadis 4
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Cold Forming & UHSS for lightweight steel applicationsFebruary 2004
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Tier 1 supplier for automotive components and modules
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GESTAMP AUTOMOCION
Tooling
R&DCommercial office
Big Stamping
HydroformingTailored Blanks
Protection
Assembling & Systems Small & Medium Stamping
Year 2003: 1250 M turnover
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GESTAMP AUTOMOCION: Centers R&D
4 Centres R&D Abadiano (Spain)
Abrera (Spain)
Westerburg (Germany)
Meudon ( France )
Staff 56 Employees in R&D activities.
Simultaneous Research with Universities and Technical Centers :
( CTM; CASTMOLD; LABEIN; IFU; IDIADA)
( ROBOTIKER; INASMET; CIDAUT; CTAG )
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GESTAMP AUTOMOCION: R&D Activities
Product Development Pedal Assembly, Mobile Parts, Subframes, Axles,Instrument Panel Beam,Bumper Beam Systems, others .
Advanced Technologies Development
Hydroforming, Tailored Blank, Hot Stam
Patchwork, Laser Welding, ping, Roll Forming, HSS Stamping, New materials
Advanced Technologies Research
Die Casting Magnesium; Aluminium; others ..
Co-Development with the Customer VW / SEAT; OPEL / FIAT; FORD;PSA; RENAULT / NISSAN ;
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ENGINEERING SERVICES
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LASER WELDED TAILORED BLANKS
BLANKING
TOOLING
HYDROFORMINGSTAMPING
PROTECTION
MODULE ASSEMBLY
Total collaboration with our customersStarting from the concept and development phase we offer to our customers our project teams and simultaneous engineering service controlling all the value chain, supplying all our know-how together with all our experience in the different technologies and responsibilities through the whole production process.
VALUE CHAIN
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R&D. PRODUCT DEVELOPMENT
Dashboard crossmember
Engine subframe
Pedal boxes
Rear bumper module
Outer panels
Vehicle systems
Front bumper module
Hood
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R&D. TECHNOLOGIES
Roll FormingTooling Cold/Hot Forming
Hydroforming
ProtectionTailored Welded Blanks
Laser welding Patchwork
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HYDROFORMING
Rp0.2%=180MPa RM=500MPaMild High Strength Steel HSS
Steel
Ultra High Strength Steel UHSS
RM =1400MPa
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400
IF
P & BH
Microalloyed
CURRENT INDUSTRIAL PRODUCTION
Dual Phase
TRIP
DESIGN & PROTOTYPING
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R&D Project HYDROFORMING
HSS Tube Hydroforming
HSS Tube Preforming
HSS Tube Bending
High Strength Steel Tubes try-outs:HSS Engine cradle validation
Prototyping trials on February 2003
Prototyping Hydroforming tubes trials for Chassis application by the usage of HSS :
- Dual Phase 600
Product innovation and Processes Synergy
Tube dimensions : 60 x 2 x 2240 mm.
Processes :
Tube Bending by 2 steps
Tube Preforming by press of 450 Tn
Tube Hydroforming by press of 5000 Tn
No high Spring back effect at the end tube
1,5mm spring back at the ends tube by the
usage of DP600 material.
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HYDROFORMINGInstrument Panel Beam
Gestamp trials on March-April 2004.Prototyping Hydrofoming tubes trials for Instrument Panel application by the usage of HSS.Trials with same material from different suppliers.
Product innovation and Processes SynergyTube dimensions : 73 x 1 x 1300 mm (DOCOL 600 DL)
73 x 1 x 1300 mm (DP600)Processes :Tube Preforming by hydroforming press of 3500 Tn (600bar). With axial feeding.Tube hydroforming by press of 3500 Tn (1600bar).
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ROLL FORMING + BENDING
Rp0.2%=180MPa RM=500MPa
Mild High Strength Steel HSS Ultra High Strength Steel UHSS
RM =1400MPa
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400
Microalloyed
CURRENT INDUSTRIAL PRODUCTION
Dual Phase
TRIP
Complex Phase
Martensitic Steel
DESIGN & PROTOTYPING
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TOOL 1: PUNCHING/CUTTING
TOOL 3.-PUNCHING/CUTTING ON FINAL PIECE
TOOL 2.- ROLL FORMING
Roll Forming lines at Gestamp Automocin
9 Up to 20kW9 Modular design
TOOL 4.- TWISTING STAND
ROLL FORMING: PROCESS
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ROLL FORMING: PROCESS
Roll Forming: flat sheet formed into a profile by successive folding operations
Decoiling Straightening Roll Forming Auxiliary operations
Roll Forming ToolRoll Forming Flower
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PRODUCTS
Side rails
Waist Reinforcement
Floor cross member
Roof cross member
Front bumper
Rear bumper
DP 1000 1.5 mm
A-pillar
ROLL FORMING + BENDINGROLL FORMINGComplexity
Front bumper
Rear bumperFront bumper
Rear bumper
Geometry
1D open profile
1D closed profile
2D open profile constant radius
2D open profile non-ct radius
2D close profile non-ct radius
2D close profile ct radius
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HOT STAMPING
Usibor 1500P
Rp0.2%=180MPa RM=500MPa
Mild
IF
P & BH
Microalloyed
High Strength Steel HSS
Dual Phase
TRIP
Complex Phase
Martensitic Steel
Ultra High Strength Steel UHSS
RM =1400MPa
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400
Ferritic-Bainitic
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HOT STAMPING
USIBOR 1500 Pafter Heat TreatmentProperties in-use
USIBOR 1500 Pafter Heat TreatmentProperties in-use
Yield Strength
(MPa)
Ultimate Tensile Strength (MPa)
300 500 700 900 1100 1300 1500 1700
900
800
700
600
500
400
300At delivery
1400
1300
1200
1100
1000
Forming Properties
Yield Strength
(MPa)
Ultimate Tensile Strength (MPa)
300 500 700 900 1100 1300 1500 1700
900
800
700
600
500
400
300At delivery
1400
1300
1100
1000
Forming Properties
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HOT STAMPING: PROCESS KNOW-HOW
HEATING PROCESS: time, temperature
COOLING PROCESS: cooling rate
COMPARISON BETWEEN STANDARD GRADE (S355) AND USIBOR 1500P
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HOT STAMPING: PROCESS KNOW-HOW
V85= 20 C/s. 424 HV1 V = 30 C/s. 437 HV1 V = 40 C/s. 462 HV1
2 mm
6 m ~ 600 HV
-20-22 m ~ 60 HV
~ 170 HV200g
USIBOR 1500
2 mm
~ 170 HV200g
Pre-coatingPre-coating
USIBOR 1500P
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HOT STAMPING: PROCESS KNOW-HOWThe conception of the bumper has been realized by GESTAMP (sizes, thickness, shape,)
Dies manufacturing done by Gestamp-Araluce
First prototypes: January 2003MATERIAL : USIBOR 1500
Yield strength: 1060MPa
Tensile strength: 1500 MPa
El %: 5
Thickness : 2,5mm
BLANKHOLDER PRODUCTION OVEN: 20C 950 C
600 t HYDRAULIC PRESS (by blank)
SUPERVISION
150 m2 FOR PRODUCTION LINE
WATER COOLED TOOL
BLANKHOLDER PRODUCTION OVEN: 20C 950 C
600 t HYDRAULIC PRESS (by blank)
SUPERVISION
150 m2 FOR PRODUCTION LINE
WATER COOLED TOOL
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LWTB, PATCHWORK
Rp0.2%=180MPa RM=500MPaMild High Strength Steel HSS Ultra High Strength Steel UHSS
RM =1400MPa
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400
IF
P & BH
Microalloyed
Dual Phase
TRIP
Complex Phase
Ferritic-Bainitic
CURRENT INDUSTRIAL PRODUCTION
Usibor 1500P
PROTOTYPING
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LWTB, PATCHWORK
CPW800 2.25 mm
CPW800 3.0 mm
StO7 1,65 mm
St070,90 mm
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COLD STAMPING
Rp0.2%=180MPa RM=500MPa
Mild High Strength Steel HSS Ultra High Strength Steel UHSS
RM =1400MPa
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400
IF
P & BH
Microalloyed
Dual Phase
TRIP
Complex Phase
Ferritic-Bainitic
CURRENT INDUSTRIAL PRODUCTION
Martensitic Steel
DESIGN & PROTOTYPING
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MANUFACTURING PLANTS
Production Plant of H.S.S. Parts: Production Plant of H.S.S. Parts: MB.MB.SantpedorSantpedor ( Spain )( Spain )
Four Transfer Presses:1 Rovetta 2400 tn year 20011 Fagor 1500 tn year 20032 Arisa 1250 tn year 1998 - 1999
HSS Area
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MANUFACTURING PLANTS
HSS Stamping Area
Welding Area
Production/Welding Plant of H.S.S. Parts: Production/Welding Plant of H.S.S. Parts: MB.MB.AbreraAbrera ( Spain )( Spain )
Press Line G2: ( year 2001 )1 Rovetta 2000 tn5 Weingarten 800 tn1 Krupp 1600 tn
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HIGH STRENGTH STEEL PARTS
High Strength Steels Parts manufactured in Gestamp Group: High Strength Steels Parts manufactured in Gestamp Group:
Door ReinforcementDoor Reinforcement8 parts
2 parts in DP780 (1.35/1.25)1 part in TRIP800 (1.35mm) 1 part in DOGAL800 (1.35)2 part in DP600 (1.35mm) 2 part in DP450 (1.0mm)
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HIGH STRENGTH STEEL PARTS
High Strength Steels Parts manufactured in Gestamp Group: High Strength Steels Parts manufactured in Gestamp Group:
Rail Side ReinforcementRail Side Reinforcement3 parts
1 part in DP600 (1.2 mm)2 parts in DP450 (1.6 mm)
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HIGH STRENGTH STEEL PARTS
6 parts
2 parts in CPW800 (3/2mm) 2 parts in TRIP800 (1.5/2mm) 1 part in DP500 (2mm)1 part in DP450 (1.75mm)
High Strength Steels Parts manufactured in Gestamp Group: High Strength Steels Parts manufactured in Gestamp Group:
B Pillar ReinforcementsB Pillar Reinforcements
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HIGH STRENGTH STEEL PARTS:DESIGN
Stamping process (TRIP800): Big addendum, big blank shape, in order to avoidspringback.
Avoid warping designs
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HIGH STRENGTH STEEL PARTS:DESIGN
Avoid Cam trimming: Maintenance very expensive!
Scrap material
Cam trimming
Drivers Binder
Cam Piercing & Trimming
Cam Piercing & Trimming
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HIGH STRENGTH STEEL PARTS:DESIGN
Gradual shape transitions and Open Ends (to reduce press force)
Gradual shape transitions
Open End Good for HSS.
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HIGH STRENGTH STEEL PARTS:DESIGN
The minimum die over bend for springback compensation depends on the tensile strength of the steel & on the thickness:Less thickness more springback, more tensile strength morespringback!!.
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DRAWING DIES: NEW MATERIALS
The drawing die must be stronger, well guided, with The drawing die must be stronger, well guided, with better materials and coated (PVD or CVD).better materials and coated (PVD or CVD).
Die 1.2379 / 1.2382VANADIS 10 (CVD)
Binder 1.2379 (D2) (CVD)
Punch 1.2314 (GP4M)
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TRIMMING DIES: NEW MATERIALS
The trimming die must be very well set up, with better The trimming die must be very well set up, with better materials and, in some cases, coated (PVD).materials and, in some cases, coated (PVD).
Trimming tool support 1.2379 / 1.2769
Binder 1.2379 (D2)
Trimming tool VANADIS 4
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R&D. TECHNOLOGIES
Trimming & Drawing Dies for HSS: Powder metallurgical Trimming & Drawing Dies for HSS: Powder metallurgical steels (steels (UddeholmUddeholm).).
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DIES FOR HSS:NEW MATERIALS
Breaks in the trimming dies (mainly in cam trimming): Breaks in the trimming dies (mainly in cam trimming): 1.2379 Steel (D2) (This steel is not enough ductile).1.2379 Steel (D2) (This steel is not enough ductile).
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DIES FOR HSS:NEW MATERIALS
The new trimming dies: VANADIS 4 ( Breaks appear 4 The new trimming dies: VANADIS 4 ( Breaks appear 4 -- 6 6 times later that with 1.2379).times later that with 1.2379).
PVD
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