Escolar Documentos
Profissional Documentos
Cultura Documentos
Ravir Bhatnagar
Ispat Inland Inc.
a subsidiary of Ispat International, N.V.
www.autosteel.org
Outline
Background
Production Implementation
- Issues and solutions
General aspects of DP500 Formability
Summary
www.autosteel.org
Drivers for Improved Dent Resistance
www.autosteel.org
Efforts to Improve Dent Performance
www.autosteel.org
Steel Tensile Properties
600
DP500
Engineering Stress, MPa
500
400
BH210
300
200
DQSK
100
0
0 10 20 30 40 50
Engineering Strain, %
www.autosteel.org
DP500 Doors Implementation Steps
www.autosteel.org
Door Feasibility Study - Conclusions
www.autosteel.org
Production Implementation
Stamping/Forming Observations
Issues
Select Solutions
Tooling Modifications
General Guidelines
www.autosteel.org
Forming Issues
www.autosteel.org
Stamping Issues Identified
Split/Tear
Edge splits noticed in the trim/flange operations
in stretch flange area on RH panel.
www.autosteel.org
Draw-die Modification
Fig. #1
www.autosteel.org
Draw-die Modification
Fig #5
www.autosteel.org
Trim-die Modification
www.autosteel.org
Trim-die Modification
Re-nested (welded)
the sail area to
provide support
to the metal and
avoid burrs on the trim
edge and edge cracking
www.autosteel.org
Flange-die Modification
Re-contour Punch/Radii
#4 Flange - Upper Die
www.autosteel.org
FLD Results 0.80mm DP500
Safe Panel
Failure
Failure
Marginal
Marginal
Worst Case Marginal
www.autosteel.org
Other General Forming Aspects
Press loads
Forming in the draw die
Die wear
Post-forming operations
Springback
www.autosteel.org
Stamping Press Loads
Considerations for DP500
DP500 exhibits higher work hardening behavior
Important for
Estimating the press capacity needed for a part
Product engineers like to down gage when applying
DP500
Estimating press loads
Use of FEA
Empirical equations (used in tool shops)
Experience
Closure panels (~ 15% increase at the same gage)
Type of operations that are being performed
www.autosteel.org
Draw-die Formability
Impact of DP500
www.autosteel.org
Die Wear and Tear
Impact of DP500
Die wear
Draw beads
Radii
Such as at the die entry
Features with small radii local contact loads can be
very high
In parts prone to wrinkling the die wear can
be an issue
Increased load response
Attention to die process to minimize wrinkle can
be very important
www.autosteel.org
Post-forming Operations
Trimming
Flanging
Hemming
Re-strike operation
Embossing
Coining
www.autosteel.org
DP500 Trimming
www.autosteel.org
DP500 Flanging
Straight flange
Not an issue
Curved flange
Stretch flange
Compression flange
www.autosteel.org
Flanging - Stretch Flange
www.autosteel.org
Flanging Curved Flange
RH Door
DP500
LH Door
DP500
www.autosteel.org
Stretch Flanging Metal Gainer
www.autosteel.org
Stretch Flanging for DP500
www.autosteel.org
DP500 - Springback
Flange
Has not been a major issue
Compensated by over bend of the flange
CMM checks of the assembly of
production trials
No issues
www.autosteel.org
Summary Mustang Doors
www.autosteel.org
Summary - General
Unique microstructures
Unique mechanical behavior
Good understanding of the metal flow
FEA simulation very informative
Engineer the process and design to
accommodate the DP500
So as to make the forming system robust
www.autosteel.org
Acknowledgements
Team Members
Greg Blizman (DSP Tooling) Michael Coats (DSP Quality)
Bruce Dudley (DSP ME) Allan George (DSP Quality)
Frank Gustaferro (DSP Quality) Sergio Latorre (DSP Tooling)
Azfar Qamar (NA Prod. Engg)
www.autosteel.org