Research for Industry and Government Stamping · PDF fileTribology (Friction, Tool Wear)

ERC

NSM

© Copyright Engineering Research Center for Net Shape Manufacturing, 2002. All rights reserved.

ERC/NSM Activities

Stamping Hydroforming MachiningForging

Research for Industry and Government

ERC

NSM


ERC/NSM Activities in Tube Hydroforming

1. Materials Determination of material flow stress data for tubular materials with

Hydraulic Bulge Test at room temperature

Determination of material flow stress data at elevated temperatures

2. Tribology (Friction, Tool Wear) Improvement of Tribological Conditions in Tube Hydroforming by Using

Environmentally Friendly Lubricant Systems and Textured Tubes

Viability of the Twist Compression Test for Screening Tube Hydroforming

Lubricants

3. Process Modeling / Tool and Process Design Simulation of T shape hydroforming

Simulation of Y shape hydroforming

Simulation of hydroforming an exhaust pipe component

Simulation of hydroforming a cross member

Simulation of hydroforming a structural member

Simulation of hydroforming a roof frame section

ERC

NSM


1. Materials/Flow Stress and

Formability - Hydraulic Tube Bulge Test -

Hydraulic Bulge Test Equipment

•Determination of Flow Stress of Tubes for Hydroforming

http://nsm.eng.ohio-state.edu/TPJ_article_flowstress.pdf

ERC

NSM


1. Materials/Flow Stress and

Formability - Hydraulic Tube Bulge Test -

Potentiometer with Thermocouple

Die and Die Holder

Punch with heating

elements

Hydraulic Cylinder

Insulator (hard

wood)

Flow stress and material formability at elevated temperatures

ERC

NSM


P = 11.9 MPa

17 % Exp.

t = 0.486 mm

P = 14.3 MPa

28 % Exp.

t = 0.427 mm

P = 13.1 MPa

23 % Exp.

t = 0.448 mm

P = 16.5 MPa

40 % Exp.

t = 0.379 mm

P = 18.3 MPa

55 % Exp.

t = 0.320 mm

Diameter : 2.250” (57.15mm)

Thickness : 0.024” (0.60mm)

1. Materials/Formability of

304 Stainless Steel

ERC

NSM


Main Research Activities:

Improvement of Tribological Conditions in Tube

Hydroforming by Using Environmentally Friendly

Lubricant Systems and Textured Tubes

Viability of the Twist Compression Test for Screening

Tube Hydroforming Lubricants

2. Tribology

ERC

NSM


2. Tribology/Friction and Lubrication

Friction conditions at different contact locations

Due to different tribological conditions at the Guiding, Transition and

Expansion zones, different lubrication tests are needed.

ERC

NSM


Load Cell

Pressure

Transducer

Rod

Tube

Die-Insert

pi

Fa Fa

Ff

pi

Fa Fa

Ff

saxsax

FFR FFRFFR FFR

2. Tribology/Tooling for Lubrication

Test - Guiding Zone -

ERC

NSM


2. Tribology/Lubricant Evaluation- Test Results for LCS 1008 -

Internal Pressure p = 600 bars Sliding Velocity v = 65 mm/s (2.5 in./s)

0.000

0.010

0.020

0.030

0.040

0.050

0.060

0 20 40 60 80 100 120

Sliding Length (mm)

Co

eff

icie

nt

of

Fri

cti

on

m

Lub E

Lub D

Lub A

Lub B

ERC

NSM


2. Tribology/Limiting Dome Height Test - Transition Zone -

ERC

NSM


Initial blank

(Circular blank with hole at the

center)

Stretched blank

(Change in hole diameter)

Punch

Die

Clamping ring

2. Tribology/Modified LDH test

- Transition Zone -

ERC

NSM


2. Tribology/Tooling for Lubrication

Test - Expansion Zone -

Pear Shaped Expansion Test

ERC

NSM


2. Tribology/

Pear-Shaped Expansion Test

Lubricant Performance as a function of Protrusion Height

68

68.5

69

69.5

70

70.5

71

71.5

72

72.5

Lub A Lub E Lub D Lub B No Lub

Lubricants

Pro

tru

sio

n h

eig

ht

PH

[m

m]

Specimen material SS304

Increasing interface friction

PH

Increasing interface friction

ERC

NSM


2. Tribology/Twist Compression

Test (TCT) - Principles of Operation -

Fr

T

*m

r

T

F

ERC

NSM


2. Tribology/TCT Samples

Before Test After Test

Material: AISI 1010 CR

Pressure: 500 bar

Sliding Velocity: 17 mm/s

Sliding Length: 160 mm

ERC

NSM


3. Process Development

and Modeling

Process Development Forming Limit Diagrams

Process limits and control

Prediction of process parameters

Process simulation using FEA

Innovative THF

Warm THF for processing Mg alloys

Engineered tubes with varying wall thickness in

circumferential and longitudinal directions

ERC

NSM


Process Development Considerations

Material characteristics

Workpiece geometry

Interface friction coefficient / lubrication

Process parameters (loading paths for axial feed,

internal pressure and counter punch application)

Die design considerations

Press capacity and characteristics


and Modeling

ERC

NSM


Process Modeling

THF of fitting components

T- Shape (DEFORM 3D)

Y- Shape (PAM-STAMP)

THF of medium size automotive components

Exhaust Pipe (PAM-STAMP)

THF of large size automotive components

Cross member (PAM-STAMP)

Structural Part (PAM-STAMP)

Roof Frame (LS-DYNA)


and Modeling

ERC

NSM


3. Process Modeling /THF of T

Shape

Part Name: T fitting

Software: DEFORM3D

ERC

NSM


3. Process Modeling /THF of T

Shape

Part Name: T fitting

Software: DEFORM3D

ERC

NSM


Part Name: Exhaust Part

Software: PAM-STAMP

3. Process Modeling /THF of an

Exhaust Part

ERC

NSM


3. Process Modeling /THF of a

Cross Member

Part Name: Cross Member

Software: PAM-STAMP

Lower Die

Upper Die

Side Wall

Side

Wall

Tube (Workpiece)

Pre-forming Calibrating / Hydroforming

ERC

NSM



Cross Member


Software: PAM-STAMP

Pre-forming


ERC

NSM



Cross Member


Software: PAM-STAMP


Hydroforming

ERC

NSM


Part Name: Structural Part

Software: PAM-STAMP


Structural Part

Bending Calibrating / Hydroforming

ERC

NSM



Software: PAM-STAMP


Structural Part


Bending

ERC

NSM



Software: PAM-STAMP


Structural Part


Hydroforming

ERC

NSM



Roof Frame Section

Part Name: Roof Frame

Software: LS-DYNA

ERC

NSM



Roof Frame Section

Part Name: Roof Frame

Software: LS-DYNA

Research for Industry and Government Stamping · PDF fileTribology (Friction, Tool Wear)

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