w w w . a u t o s t e e l . o r g w w w . a u t o s t e e l . o r g Great Designs in Steel is Sponsored by: AK Steel Corporation, ArcelorMittal Dofasco, ArcelorMittal USA, Nucor Corporation, Severstal North America and United States Steel Corporation
30
Embed
Great Designs in Steel is Sponsored by AK Steel .../media/Files/Autosteel/Great Designs in Steel... · AK Steel Corporation, ArcelorMittal Dofasco, ArcelorMittal USA, ... Progressive
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
w w w . a u t o s t e e l . o r g
w w w . a u t o s t e e l . o r g
Great Designs in Steel is Sponsored by:AK Steel Corporation, ArcelorMittal Dofasco, ArcelorMittal USA,
Nucor Corporation, Severstal North America and United States Steel Corporation
w w w . a u t o s t e e l . o r g
Tailor Welded Coils:Tailor Welded Coils:Applications, Results & Body Structure ImpactApplications, Results & Body Structure Impact
Mark EisenmengerTWB Company LLC
w w w . a u t o s t e e l . o r g
Agenda
Review Tailor Welded Blank Applications
Evolution of Tailor Welded Blanks to Tailor Welded Coils
Application and Results of Tailor Welded Coils
BIW Impact with Tailor Welded Coils
w w w . a u t o s t e e l . o r g
Tailored Product Benefits
GeneralProduct Benefits
Part Reduction/IntegrationMass/Weight SavingsImprove Functionality
Manufacturing BenefitsReduce Manufacturing Complexity Improve Dimensional Control
Cost BenefitLower Tooling & LaborReduce Number of OperationsLess Material Handling & Enhanced Logistics
Material Cost Reduction (MCR)Improved Material Utilization
NestingScrap Reduction
• Optimize Steel Properties Throughout the Part
w w w . a u t o s t e e l . o r g
Tailor Welded Blank Applications
There are 18 common tailor welded blank automotive applications
w w w . a u t o s t e e l . o r g
Welding Process
Butt Weld (no filler)Continuous Flow Welding processGauge Possibilities: 0.4mm to 3.5mmWeld Lengths – up to 4 metersMaterial Combinations Include:
Stainless CR, HR, Zn Coated, DP, TRIP,CP and boron gradesEach weld is computer monitored and serialized
Result: Six Sigma Quality Levels (External PPM 3 or less!)
w w w . a u t o s t e e l . o r g
Tailor welded coils provide specific product benefits:
Exact grade, coating and gage of steel where it is needed.
Cost reduction with part consolidation.
Lighter weight and improved part performance.
Tailored products in coil fed products such as progressive die and roll-forming.
A Breakthrough ProcessTailor Welded Coils:
w w w . a u t o s t e e l . o r g
Continuous process that consists of:
Un-coiling / LevelingWelding Re-coiling
Process OverviewTailor Welded Coils:
Monitoring &Reporting
w w w . a u t o s t e e l . o r g
Utilize the same quality criteria for tailor welded blanks and tailor welded coilsWeld defects are identified and mapped for each coilThe result is improved material utilization with minimal material loss
Coil Map
Quality MonitoringTailor Welded Coils:
w w w . a u t o s t e e l . o r g
Weld defects are identified and mapped for each coil with customer specified methods
There are more than 35 potential tailor welded coil automotive applications
w w w . a u t o s t e e l . o r g
Potential Applications for TWC
Seat tracks, supports and seat frames Door intrusion beamsDoor belt reinforcementRoof headers and railsRoof cross railsPlenum floorBumper beamsSillsFloor pan strainerChassis componentsRail back platesSun roof reinforcements
Door beam
w w w . a u t o s t e e l . o r g
Progressive Die Operation
Coil fed operations with tailored steel enable:
lower die & assembly investmentmaterial savingspart weight savingsimproved part performanceimproved dimensional control
Finished PartTailored Coil
w w w . a u t o s t e e l . o r g
Progressive Stamping TWC Parts
Saves 2.0 pounds / vehicleSaves $1.50 / vehicle2 parts / vehicleIn production (Germany)
Longitudinal Chassis Beam
w w w . a u t o s t e e l . o r g
1.35 mm
Roof Cross Member
Progressive Stamping TWC Parts
1.0 mm1.35 mm
Integrates 3 stampings into 1
Improved roof crush and side impact resultsSaves .8 lbs / vehicleSaves $1.60 / vehicleIn production (Germany)
w w w . a u t o s t e e l . o r g
Part developed by .dwg Design Services
Roof Bow
Progressive Stamping TWC Parts
1.8 mm1.0 mm
Integrates 3 stampings into 1
Improved roof crush and side impact resultsSaves 2.0 lbs / vehicleSaves $2.25 / vehicleProposed (USA)
1.8 mm
w w w . a u t o s t e e l . o r g
Improves part stiffnessConsolidates 2 stampings into 1Eliminates assemblyStainless steel 439 Saves .25 lbs / partSaves $.95 / vehicleProposed (USA)