Introduction of EWI Forming Center

November 14, 2012 Ron Brown Director EWI Forming Center Office 614-688-5085 E-mail: rbrown@ewi.org Hyunok Kim Technical Director EWI Forming Center Office: 614-688-5239 E-mail: hkim@ewi.org
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Background
Presidents Council of Advisors on Science and Technology JULY 2012 REPORT TO THE PRESIDENT ON CAPTURING DOMESTIC COMPETITIVE ADVANTAGE IN ADVANCED MANUFACTURING

- 11 Top Cross-Cutting Technologies pivotal in enabling U.S. manufacturing competitiveness

Advanced Forming And Joining Technologies

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Background
Meeting the challenge thru collaboration EWI & OSU

EWI Forming Center

OSU Center For Precision Forming

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Background
Meeting the challenge thru collaboration EWI & OSU Unique in the western hemisphere
EWI Forming Center
Chairman - Dr. Taylan Altan Director Ron Brown Technical Director Dr. Hyunok Kim

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Mission
The mission of the center is to develop and advance innovative forming processes, tooling, and equipment; provide a technology and knowledge base to industry and government; and cooperate with the Ohio State Universitys Center for Precision Forming (OSUCPF) to conduct fundamental research while training new engineers for the forming industry.

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Strategy
Establish Forming Center at EWI in cooperation with CPF-Center for Precision Forming of OSU Provide the knowledge base and infrastructure that exists at EWI and CPF (160 ton hydraulic press and tooling moved to EWIs laboratory) Establish cooperation with EWI and CPF staff and students to conduct projects for industry and government Utilize the strengths of both EWI and CPF in technology as well as business. Thus, while establishing and expanding the EWI-CPF continue to maintain CPF as the university link and fundamental research support. Continue to maintain and expand the close cooperation EWI and CPF have with companies interested in joining and forming technologies.
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Structure of EWI Forming Center

NSF/ other government
Close cooperation

EWI-Joining R&D EWI-Members

Automotive Aerospace Energy

EWIForming Center

CPF-OSU
Industry, 15 companies

Activities-R&D in Sheet Forming

Material characterizations/ formability Friction/lubrication Process simulation/quality/springback Fabrication

(OEM/s, 1ST Tier, software, tooling)

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Activities of EWI Forming Center

EWI-Forming Center and CPF-OSU Activities in R&D Effort EWI-Forming Center

CPF-OSU

From R&D to Production Basic R&D Proof of concept Lubrication application Prototyping (pre-production) 8
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Next Step
Create a Forming Center website Establish a group of friends of the Center Hold a semi-annual workshop (Next in March 2013) Email quarterly R&D updates Publish industry-related non-proprietary results

The centers inaugural event, a joint workshop with OSU-CPF on Advance Sheet Metal Forming Technology at EWI headquarters on November 14, 2012.
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Forming Equipment at EWI

Type
Slide Force

Minster Tranemo DPA-160-10

160 metric tons (176.4 tons)

Cushion Force 100 metric tons (110.3 tons) Eject Force Slide Speed Slide Stroke Platen Size Test tooling 15 metric tons (16.5 tons) 90 mm/s maximum (3.54-inch/s) 500 mm (19.68 inch) 1,000 x 1,000 mm (39.37 x 39.37 inch) 7 different testing die sets available with the press

160-ton Minster Tranemo Press (Installed at EWI in Sept. 2012)

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Forming Test Capabilities

Formability tests: Tensile (up to 1000F) test Biaxial bulge test Billet upsetting and extrusion tests Friction, Lubrication and Tool wear tests Strip galling test Deep drawing test Limiting Dome Height (LDH) test Ironing test with heated dies Double cup extrusion (DCE) test Stamping tests Bending and Flanging tests Rectangular deep drawing test Springback tests
Biaxial Bulge Tested Sample (12-in x 12-in) Deep Drawn Sample (6-in bottom dia. x 3.5-in. depth)

Rectangular Drawn Sample (20-in. x 18-In. x 2-in. depth)

DCE Tested Sample (1-in. dia. x 2.5-inch height)

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Simulation Capabilities
Process Simulations FEM of automotive part Sheet Metal Forming - Springback - Failures (necking and wrinkling) - Tool stress and wear - Tool design and process optimization S-rail stamping simulation Bulk Metal Forming (Forging) - Die stress and temperature distribution - Optimized die shape FE Modeling Tools - ABAQUS - DEFORM - LS-DYNA
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Questions?
Ron Brown Director EWI Forming Center Office 614-688-5085 E-mail: rbrown@ewi.org Hyunok Kim Technical Director EWI Forming Center Office: 614-688-5239 E-mail: hkim@ewi.org

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