CPF Center for Precision Forming

(www.cpforming.org) Taylan Altan, Director (email: altan.1@osu.edu)

A short Review July, 2011

Introduction

CPF

The Ohio State University (OSU) and have established the Industry/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) and member companies. CPF (www.cpforming.org) benefits from research conducted at Engineering Research Center for Net Shape Manufacturing (ERC/NSM www.ercnsm.org).

Objectives

CPF

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.

Current 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

CPF

Current Projects
Objective:

CPF

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

Develop guidelines for elevated temperature sheet forming (process optimization, lubricant evaluation and Finite Element Modeling)

Warm deep drawing (in cooperation with AIDA Engineering, Ltd.) 5

Current Projects
Objectives:

CPF

CPF 1.4: Investigation of springback in forming Advanced/High Strength Steel (A/HSS)

Determine the variation of Youngs Modulus with deformation /strain Predict and reduce springback in stamping A/HSS

Planned experiments (Tool concept)

1. Straight flanging 2. Stretch flanging 3. Shrink flanging

4. Straight hat shape drawing and stretching

5. Curved hat shape drawing and stretching

Current Projects
Objective:

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

Sheet bulge test (Viscous Pressure Forming VPF)

Current Projects

CPF

CPF- 2.2: Determination of flow stress of Al and Mg sheet materials at elevated temperatures Objective:
Determine flow stress of sheet materials at elevated temperatures for the warm forming process. Hole

Modified Limiting Dome Height (MLDH) Test Inverse Analysis Technique Formed sample (OD = 14in, t0 = 0.034in) 8

Current Projects
Objective:

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
Micrograph of galled surface

Tool surface
P rm

Twist compression Test (TCT)

(in cooperation with IRMCO)

Galling
Testing materials: DP 600 Bare with Lub A

Testing conditions: P = 170 MPa & N= 8.9 RPM

Current Projects

CPF

CPF - 4.1: Multi Point Control (MPC) die cushion and blank holder technology in stamping Objective:
Develop an automated system to optimize the Blank Holder Force for robust stamping
Die

Blank holder / Binder

Individual hydraulic cylinders for each cushion pin

Location of cushion pins/ cylinders in the die

(continue)

(Source: Mller Weingarten) Proposed system for robust stamping using MPC

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Current Projects

CPF

CPF - 4.1: Multi Point Control (MPC) die cushion and blank holder technology in stamping (continue)
Parts formed with OSU software by USCAR (try-out reduced from 3 days to 3 hours)

Al 6111-t4 (t = 1 mm)

BH210 (t = 0.81 mm)

DP500 (t = 0.78 mm)

Sample parts [GM lift gate inner panel] with different materials and sheet thickness was formed in the same die by simply adjusting the BHF.

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Current Projects
Objective:

CPF

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

Utilize past R&D experience at OSU to assist interested companies in introducing and/or improving the hydroforming technology

A.

C.

B.

D.

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

[Leitloff , 1997 ]

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Center for Precision Forming CPF

(CP-Forming-www.cpforming.org)

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.)

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