edge cracking study, fgu stuttgart coil servicecenter gmbh...an autoform r7 simulation: door inner...
TRANSCRIPT
www.mn-coil.de
Benefit from the advantages of high-speed
cutting by MN Coil Servicecenter, proven
by Forschungsgesellschaft Umformtechnik
Stuttgart:
• 20% higher rest formability at the edge
of the blank compared to laser cutting
• up to 5% material savings
• higher process reliability
• shorter simulation time
20%HIGHER REST
FORMABILITY
Edge cracking study, FGU Stuttgart
DIABOLO test - Edge Conditions
Coil Servicecenter GmbH
High-precision 2D aluminum blanks
Coil Servicecenter GmbH
Best forming results through HSC cutting
Sheet thickness 0.5 - 5.0 mm
Cut to width Customized blanksCut to length
Length 150 - 8,000 mm
Width uo to 2,050 mm
Length 500 - 8,000 mm
Step 1
Width > 100 mm x 6
Length up to 4,000 mm
Width up to 2,000 mm
Step 2 Step 3
MN Coil Servicecenter GmbH is one of the most modern
coil centres in Europe and the specialist for high-preci-
sion 2D aluminum blanks. MN Coil Servicecenter is
your partner for:
• Series where the procurement of cutting tools would
be uneconomical
• Series ramp-ups where the use of cutting tools has
not yet been decided
• Reworking for special vehicles and models
• Spare part requirements
• Bridging of delivery bottlenecks
• Exclusive and small series
MN Coil Servicecenter GmbH
is certified to
• IATF 16949 and
• DIN EN ISO 9001:2015
MN Coil Servicecenter GmbH
Industrieweg 34 I D-23730 Neustadt
Tel.: +49 (0)4561 5179-0
E-mail: [email protected]
TÜV NORD CERTGmbH
IAT
F 16949/ISO 9
001
www.mn-coil.de
Laser CO2, output: 6kW, cutting gas: nitrogen
Water jetSystem pressure: 4000 bar
HSC milling process at MN CoilCutter Ø: 6 mm
Stamping, new tool Cutting gap: 0.06 mm, cutting edge roundness:
none
Stamping, used tool Cutting gap: 0.06 mm, cutting edge roundness:
300 µm
DIABOLO test - Setup
Optical
measuring
system
PunchPunch
Specimen Specimen Blank holder
DieDie
Total number of tests: 200
100 mm
1. The HSC method demonstrated the best results for
all alloys investigated in the DIABOLO test.
2. The cut edges resulting from the HSC method have
approximately 20% higher rest formability on average
compared to the laser cut samples.
0,000
0,100
0,200
0,300
0,400
0,500
0,600
0,700
0,800
Laser Water jet HSC Stampingnew tool
Stampingused tool
max
. deg
ree
of p
rinc
ipal
def
orm
atio
n
Three different component geometries were tested in
an AutoForm R7 simulation: Door inner part, wheel-
house and B-pillar.
The material data in the simulation software were
supplemented by the experimentally determined
measured values. This determined the edge crack
criterion.
Components are usually designed with a criterion of
0.8, i.e. 20% process safety. Cracks would occur in
the components as of a value of ≥1.
1. HSC-milled edges result in higher formability
and higher process safety, which means that
neither method optimisation nor component modi-
fications are necessary, as would be the case with
stamping.
Door inner part - relief hole
Edge crack used tool: 0.932
Edge crack HSC: 0.546
2. Components formed from HSC-cutted sheets can
be produced with harder beads and higher blank
holding forces. Stamped components in contrast
need softer beads and larger feeder which increa-
ses material consumption.
B-pillar - beads
Edge crack used tool: 1.065
Edge crack HSC: 0.624
3. HSC-milled edges lead to material savings of up
to 5%, as shown in the wheelhouse relief hole
example, as more material can flow out from the
inside during forming.
Wheelhouse - relief hole
Edge crack used tool: 1.374
Edge crack HSC: 0.755
DIABOLO test & Simulative investigation Simulative investigation
Test results
Simulative investigation
Test results
5182 1,15 mm
6016 1,70 mm
5182 1,15 mm
www.mn-coil.de
Coil Servicecenter GmbH
2D blanks made of aluminum - a growing market
The material aluminum has become one of the most
important lightweight materials in the automotive
sector over recent years, which in turn means the
demand for customized blanks is rising continuously.
The quality requirements for these blanks are also
increasing.
The Forschungsgesellschaft Umformtechnik Stuttgart
(FGU) carried out an edge cracking study in 2019 in
order to determine the quality of customized blanks
produced by MN Coil Servicecenter and their HSC
method.
The production processes involved in edge cutting and
the cut edge properties/characteristics themselves
influence the rest formability of the sheet edge.
The formability of sheet materials is reduced due to the
strain hardening caused by stamping. This increases
the crack sensitivity of edges, particularly in the case
of high and ultra-high lightweight sheet materials. The
MN Coil HSC process was compared with conventional
production processes in practical tests (DIABOLO test)
and simulative evaluations (AutoForm R7). The test
results speak for themselves.
In the DIABOLO test, the samples (4 alloys, 5 cutting
methods) were formed until an edge crack occurred
and the maximum sustainable principal deformation
before start of failure was determined.
DIABOLO test
Alloy and material thickness:
5182 1,15 mm
6016 1,70 mm
5182 1,75 mm
AL6 1,10 mm