Engineering Council

Institute of Production Technology

and Forming - Machines

Univ.-Prof. Dr.-Ing. Bernd Engel

ED_BE 1

Engineering Council

Engineering Council

07th April 2004

ED_BE 2
 Institute of Production Technology
Engineering Council
and Forming Machines

Demands of Automotive Industry

New Materials (High Strength Steel)

Demands to Forming Technology

Bending and Hydroforming

ED_BE 3

Demands of Automotive Industry Engineering Council

BMW 5-Series Body In White with High-Strength Steel Components

Hybrid Body High-Strength Steel

Structure Steel
Aluminum
New Concepts
with Profiles

Total Simulation:
From Sheet to
Crash

BMW E60, Quelle: ATZ/MTZ extra August 2003 D 58922

ED_BE 4
 Demands of Automotive Industry Engineering Council

Alloys for the Body In White of the new 5-Series

Hybrid Body
Structure

New Concepts
with Profiles

Total Simulation:
From Sheet to
Crash

Aluminium Add-on
Parts new 5 Series

BMW E60, Quelle: ATZ/MTZ extra August 2003 D 58922

ED_BE 5

Demands of Automotive Industry Engineering Council

Production Processes

Extrusion Profile
Hybrid Body Casting
Structure Hydroforming
Rollforming
New Concepts
with Profiles

Total Simulation:
From Sheet to
Crash

BMW E60, Quelle: ATZ/MTZ extra August 2003 D 58922

ED_BE 6
 Demands of Automotive Industry Engineering Council

New Steel Body

Hybrid Body
Structure

New Concepts
with Profiles

Total Simulation:
From Sheet to
Crash

VDI-Nachrichten 12. September 2003 Nr. 37

ED_BE 7

Demands of Automotive Industry Engineering Council

Ultra Light Steel Auto Body

Hybrid Body
Structure

New Concepts
with Profiles

Total Simulation:
From Sheet to
Crash

ULSAB Report

ED_BE 8
 Demands of Automotive Industry Engineering Council

Atlas – Space Frame

Hybrid Body
Structure

New Concepts
with Profiles

Total Simulation:
From Sheet to
Crash

ED_BE 9

Demands of Automotive Industry Engineering Council

Crash Simulation based on different Inputs (1)

Material Forming-Simulation
Hybrid Body
Structure properties Material
from properties
New Concepts Tensile-Test after
with Profiles of Sheet Forming-
Total Simulation: Processes
Tensile
From Sheet to Test of Part.
Crash

Various
Assumption: properties
Same over the Part
properties for depend on
Yield Forming -
Strength, Processes and
Thickness Hardening -
over the Part Effects.

ED_BE 10
 Demands of Automotive Industry Engineering Council

Crash Simulation based on different Inputs (2)

Base Mapping
Hybrid Body
Structure Crash-Simulation
New Concepts
with Profiles Mapping Data from all
Forming -Processes
Total Simulation:
From Sheet to
Crash

with Mapping
Base

ED_BE 11

Demands of Automotive Industry Engineering Council

Mapping Data for Crash-Simulation

Hybrid Body
Structure higher local
Plastifications
New Concepts without
with Profiles Mapping

Total Simulation: with Mapping

From Sheet to
Crash

Increased
wall-thickness

with Mapping

Base

ED_BE 12
 Demands to Forming Technology Engineering Council

Mapping Data from different Forming-Technologies

Use of Hardening-
Effect Stamping Hydroforming
New Bending
Concepts

Profile –
Hydroforming

Sheet –
Hydroforming
Stress [MPa]

True Strain ϕ [-]

ED_BE 13

New Materials (High Strength Steel) Engineering Council

New Materials: Chance and Challenge

Material
LSS HSS UHSS
Elongation at Fracture (%)

Properties
< 210 MPa 210 - 550 MPa > 550 MPa IF-Steel
Reduced Soft Deep Draw Steel
Formability
70
High-Strength IF-Steel
60 BH-Steel
Isotropic Steel
50 CMn
40 High-Strength Micro Alloyed Steel
DP-/MP-Steel
30 TRIP-Steel
Martensite Steel
20

10

0
0 200 400 600 800 1000 1200
Elastic Limit (MPa)
ED_BE 14
 New Materials (High Strength Steel) Engineering Council

New Materials: Chance and Challenge

Material Flow-Curve
Properties FormLimit Curve
0,7
900

Reduced
800
0,6
Formability

Major Strain ϕ
700
0,5

600

[N/Mpa]
Stress [MPa]
0,4
500

Stress
0,3 400

300
0,2

200

0,1
100

0 0
-0,4 -0,3 -0,2 -0,1 0 0,1 0,2 0,3 0,4 0,5 0,6 0 0,2 0,4 0,6 0,8 1 1,2

Minor Strain ϕ Strain

True Strain ϕ [-]
AlMgSi05 DP600 St14

Use of new Materials: Hardening - Effect via Forming Limit

ED_BE 15

Bending and Hydroforming Engineering Council

Classification of Hydroforming

Forming with Fluids

New Bending
Concepts

Profile –
Hydroforming
Deep drawing Hydroforming
Sheet – with Fluids
Hydroforming

Hydroforming of
Sheet Hydroforming
hollow profiles

Quelle: VDI Richtlinie 3146, Blatt 1

Prospekt VIA Formtec

ED_BE 16
 Bending and Hydroforming Engineering Council

Hydroforming: Complete Process

Use of Hardening-
Effect
Tube-Forming Bending Die Closing Hydroforming Part properties
New Bending
Concepts

Profile –
Hydroforming

Sheet –
Hydroforming

Hydroforming - Process

ED_BE 17

Demands to Forming Technology Engineering Council

Profile Hydroforming

Use of Hardening-
Effect
Bending
Bending Limitation for Joining
Joining
New Bending LimitedRadii
Limited Radii Hydroforming AlternativeJoining
Alternative Joining
Concepts
Methods
Methods
Profile –
Hydroforming Hydroforming
Hydroforming
Calibration
Calibration Hydroformingwthwth Hydroforming
Hydroforming Hydroforming
Sheet – LimitedCorner-
Limited Corner- axialFeed
Feed Limited
axial Limited
Hydroforming Radii
Radii LimitedLength
Length Circumference
Limited Circumference
forExpanding-
for Expanding-
Area
Area

ED_BE 18
 Bending and Hydroforming Engineering Council

Bending – forming limits

Use of Hardening- No Mandrel Mandrel with

necessary one Ball
Effect
Mandrel with two
Balls
New Bending
Outer ∅ of the Tube
Bending Radius

Concepts
Mandrel with a Limitation
Limitationofof
Profile – couple of Balls
small
Hydroforming smallRadii
Radii
as
asaaresult
resultofof
Sheet – Bending not possible Buckling
Buckling
Hydroforming

R
Outer ∅ of the Tube
Wall Thickness of the Tube

Tendency: Tubes for Structural - Elements inrease to a Ratio greater than 90.
Ratio: Outer-Diameter to Wall - Thickness

ED_BE 19

Bending and Hydroforming Engineering Council

Bending: Forming - Limit: minimum Radius

Use of Hardening-
Effect

New Bending
Thyssen Folie - Dornm
Concepts

Profile –
Ball-Mandrel Flexible Mandrel
Hydroforming Strain

Sheet –
Hydroforming
Aktiver Faltenglätter Triboprüfstand

Flexible Mandrel to provide Buckling and enlarge Forming-Limit

ED_BE 20
 Bending and Hydroforming Engineering Council

Bending: Forming - Limits

Use of Hardening-
Effect Measurement-Box
for Normal - Forces and Friction - Forces
New Bending
Concepts

Profile –
Hydroforming

Sheet –
Hydroforming Limitation
Limitationofofbig
big
Radii Active Wiper Die
Radiias asaaResult
Result
ofoflimited
limitedTool-
Tool-
Size
Size

ED_BE 21

Bending and Hydroforming Engineering Council

Hydroforming Limits restricted through Bending - Limits

New Bending
Concepts

Profile –
Hydroforming Position 2
Sheet –
Hydroforming
Position 1

Bending-Line places the Cross - Sections

ED_BE 22
 Bending and Hydroforming Engineering Council

Hydroforming Limits restricted through Bending - Limits

New Bending
Concepts

Profile –
Hydroforming

Sheet –
Hydroforming

Positioning in Hydroforming Die – Position 1: no Cracks

ED_BE 23

Bending and Hydroforming Engineering Council

Hydroforming Limits restricted through Bending - Limits

New Bending
Concepts

Profile –
Hydroforming

Sheet –
Hydroforming

Positioning in Hydroforming Die – Position 2: with Cracks

ED_BE 24
 Bending and Hydroforming Engineering Council

Bending – 3 Rollers Bending

Positioning X

New Bending
Concepts Positioning Y
Roll 1
Feed
Profile –
Bending Roll
Hydroforming
Roll 2
Sheet –
Hydroforming
Positioning X

Bending Radii

Collision with Roll 2

Collision with Roll 1

Positioning Y

ED_BE 25

Bending and Hydroforming Engineering Council

Hydroforming – restricted Design of Radii

Internal pressure to form out inner radii

New Bending
Concepts 5000
4500 Rm=200N/mm2
Profile –
4000 Rm=400N/mm2
Hydroforming
3500 Rm=600N/mm2
pi [bar]

Sheet – 3000
Hydroforming Rm=300N/mm2
2500
2000 Rm=500N/mm2

1500 Rm=700N/mm2
1000
500
0
0 0,1 0,2 0,3 0,4 0,5 0,6

s / r [-]
Tendency: High – Strength - Steel raises the internal Pressure

ED_BE 26
 Bending and Hydroforming Engineering Council

Sheet Hydroforming

New Bending
Concepts

Profile –
Hydroforming

Sheet –
Hydroforming

ED_BE 27

Bending and Hydroforming Engineering Council

Required local Pressure over the whole Part

New Bending
Concepts Required Pressure: 400 bar
Profile –
Hydroforming Required Pressure: 150 bar
Sheet –
Hydroforming

Tendency: Big Sheets increases Clamping Force and Cycle Time

ED_BE 28
 Bending and Hydroforming Engineering Council

Future Methods to focus the Pressure

New Bending
Concepts Jet
Profile –
Lance
Hydroforming

Sheet – Sheet
Hydroforming

ED_BE 29

Bending and Hydroforming Engineering Council

Classification of incremental Hydroforming

New Bending Variant Pressure Direction Tool

Concepts

Profile – not
Hydroforming inside
necessary
Sheet –
Hydroforming

inside partial

inside complete

ED_BE 30
 Bending and Hydroforming Engineering Council

Classification of incremental Hydroforming

New Bending Variant Pressure Direction Tool

Concepts

Profile – not
Hydroforming outside necessary
Sheet –
Hydroforming

outside partial

outside complete

ED_BE 31

Bending and Hydroforming Engineering Council

Pulse Hydroforming – Pressure Distribution

New Bending
Concepts

Profile –
Hydroforming

Sheet –
Hydroforming
Pressure build
up after Unload
of a Condenser

ED_BE 32