高强度铝成形技术多功能生产线

1、高强度铝成形技术多功能生产线技术创新，变革未来高强度铝成形技术多功能生产线Multipurpose production line for high strength Aluminium forming technologies来自AP&T 的热成形技术AP&Ts HForm Technology专注于汽车行业，改变的驱动力来自于CO2 排放法规Focusing on automotive, the key driver for change is the CO2 emission regulation滚动阻力Rolling resistance气动阻力Aerodynamic resistan

2、ce车身重量Vehicle weight传动系统Drivetrain轻量化设计Design to lightweight新材料和工艺New materials and processesReduction in consumption in %0-5-10-15-20-25-30-3501020304050Change in %Dr. W. Ruch,Die Strategische Bedeutung der Al-Technologie im Karosserieleichtbau bei AUDI,2nd European Al-Automobile Conference, 2002Ve

3、hicle weightMayyas AT, Qattawi A, Mayyas AR, Life cycle assessment-based selection for a sustainable lightweight body-in-white design, 2012Ellenrieder G, Gnsicke T, Goede M, Herrmann, Die Leichtbaustrategien, 2013 轻量车身是关键A light weight Car Body is keyEnergy efficiencyLightweightSafetyOUR FOCUS汽车高强度材

4、料之旅才刚开始The journey of high strength materials in cars, has just begun.为什么不是高强度铝板的压力硬化Why not press harden high strength Aluminium?为什么需要在高温下成形，如7系铝Why should we form e.g. AA7xxx at elevated temperatures?Hot stamping - AA7075 400CWarm forming- AA7075 250CW-temper coldforming- AA7075Thickness mm2.101.9

5、21.741.561.381.201.030.8500.8-0.100.10.20.30.4Major strain -Minor strain -Source: AMAGAA-7xxx 20CAA-7xxx 170C AA-7xxx 230CAA-7xxx 400CAssumptionHigher forming limit can be achieved if AA7075 is formed at elevated temperaturesMin. thickness:1.13 mmMin. thickness:0.97 mmMin. thickness:0.62 mm高强度铝成形的车身

6、部件制造PRODUCTION OF BODY COMPONENTS FROM HIGH-STRENGTH ALUMINUM 轻量化 Lightweight 高强度 High strength 复杂零件成形-新机遇 Complex shape new opportunities工艺路线的配置 AP&T的热成形工艺Process Route Configurations AP&Ts HForm TechnologyTemperaturet1Artificial AgeingNaturalAgeingt2t3t4 t5t6TimeFormingTWFTA TESolutionization(SHT)

7、 Heat-UpSoakingTransfer to AgeingAgeingW-TemperTSHTTITMStamping ProcessAutomotive Aluminium Alloy Grades (AAxxxx)t1t1- t2t2t2- t3t3- t4t5- t6Warm5053, 5182, 5754,6016 T4, 6022 T4, 6111 T4,time to heat-up to SHTsoaking time at SHTforming/ quenching timetransfer/ air cooling time7075 T6transfer timeag

8、ing timeHot6016, 6082, 6070, 7021, 7075forming timeAP&T 的高强度铝之旅AP&Ts journey on high strength AluminiumAP&TLOCOLITECUP TOOLPRODUCTIONEWILOCOMATECH TOOLLOTUSTESTLINE CIPCOPROJECTFIATTEST ”HAT PROFILE”20132014201520162017PABLOCOLITETESTALVABBQFORMINGLOCOMATECHFIATPROCESESSPROJECTPROJECTSIMULATION20172

9、014201520162013故事是怎样开始的？2013年3月Blidsberg测试中心铝热成形测试How did the Aluminium story start? Aluminium hot forming tests at AP&Ts test centre in Blidsberg 03/20137系铝迈出的第一步First steps towards 7000 alloys 6082 and 7075 Courtesy of Fiat and LotusAP&TLOCOLITECUP TOOLPRODUCTIONEWILOCOMATECH TOOLLOTUSTESTLINE CIP

10、COPROJECTFIATTEST ”HAT PROFILE”20132014201520162017PABLOCOLITETESTALVABBQFORMINGLOCOMATECHFIATPROCESESSPROJECTPROJECTSIMULATION20172014201520162013第一个铝热成形的模拟计算First Aluminium Hot Forming FE-simulationLess thinning due to missing featuregood agreement in thickening accurate wrinkle andwrinkle flatten

11、ing predictionless thinning in biaxial stretch no anisotropy data yetAP&T 研发中心AA6082 门内板的成形AA6082 Door Inner formed at AP&T R&D centreLotus door innerMax strain according to simulation: 50% Locolite EU FP7 projectSomecrazy“ experimentsAP&TLOCOLITECUP TOOLPRODUCTIONEWILOCOMATECH TOOLLOTUSTESTLINE CIP

12、COPROJECTFIATTEST ”HAT PROFILE”20132014201520162017PABLOCOLITETESTALVABBQFORMINGLOCOMATECHFIATPROCESESSPROJECTPROJECTSIMULATION20172015201620132014挑战 磨损/擦伤Challenge - Wear / Galling 擦伤是磨损的一种形式，由滑块表面之间的粘合造成Galling is a form of wear caused by adhesion between sliding surfaces 擦伤导致表面的高粗糙度Galling causes

13、 a high surface roughness 表面高粗糙度导致高摩擦A high surface roughness leads to high friction 高摩擦导致材料失效和较差的成形部件表面质量High friction leads to material failure and low surface quality of the formed partGalling needs to be prevented!Source: University of Erlangen挑战 磨损/擦伤未涂层Uncoated不合适的润滑剂Unsuitable Lubricant涂层Coat

14、ed合适的润滑剂Suitable LubricantAP&T B-Pillar:Challenge - Wear / Galling 我们发现了正确的模具涂层和润滑剂We found the right tool coating and lubricationCup tool:GallingGallingGalling未涂层Uncoated不合适的润滑剂Unsuitable LubricantNo Galling涂层Coated合适的润滑剂 Suitable LubricantAP&TLOCOLITECUP TOOLPRODUCTIONEWILOCOMATECH TOOLLOTUSTESTLI

15、NE CIPCOPROJECTFIATTEST ”HAT PROFILE”20132014201520162017PABLOCOLITETESTALVABBQFORMINGLOCOMATECHFIATPROCESESSPROJECTPROJECTSIMULATION20172016201520132014工艺研究： 高强度铝的成形Process study: Forming of High Strength Aluminium AA7075 T6 1.2 mm 增加设计空间Increases freedom of design 确保功能整合Enables function integratio

16、n 确保最终成形Enables net shape forming如何考虑高强度铝？How to think high strength Aluminum?3 piece cold formed partAA 5xxx (gauge: x mm)Piece price:Material Production Assembly Logistics TOTAL:$ xx$ xx$ xx$ xx$ XX1 piece hot formed partMaterial: AA 7xxx (gauge: xx$ xx$ zero$ xx$ XX 20 to 30%3 x Tooling$ XX M1 x

17、ToolingJustificationHot Forming Weight Savings = 30 to 50%Hot forming enables cost and weight reduction through a holistic development approach$ XX M 20 to 30% 减少细节数量 Reduces the number of details 减少模具数量 Reduces the number of tools 更有效的搬运，物流和装配 More efficient handling, logistics and assemblyAP&TLOCO

18、LITECUP TOOLPRODUCTIONEWILOCOMATECH TOOLLOTUSTESTLINE CIPCOPROJECTFIATTEST ”HAT PROFILE”20132014201520162017PABLOCOLITETESTALVABBQFORMINGLOCOMATECHFIATPROCESESSPROJECTPROJECTSIMULATION20162017201520132014 热成形hot forming w-temper 温成形warm forming 铝(6000 and 7000)aluminum (6000 and 7000)铝热成形概念介绍Introdu

19、cing the HForm concept铝的多层箱式炉新的加热概念Aluminum MLFNew heating concept快速加热Fast heating强化固溶Solutionizing润滑/未润滑板料Lubricated / Non lubricated sheets安全定位Safe Positioning内部无移动部件No moving parts inside紧凑型设计Compact Design高可用性High AvailabilityMLFlMLFSMLF-Alu3。17131925313743495561677379859197103109115121127133139

20、145151157163169175181187193199205211217223229235241247253259265271277283289295301307313319325331353-”iACTO MATIO NPRESSmSTOO LINGb 。48gAulm niuimM LFMLF3-,MLFAlu1-MLF-AluSMLF2MLF6|MLF-Alu4.,l .Temperature Toelranceof1900 x 1600 x .12at540c伞预冷工艺Intermediate Cooling 降低节拍时间Cycle time reduction 改善摩擦条件Im

21、proved tribological condition 中等温度提高成形性 Increased formability at the intermediate temperature 提升6系和7系的机械性能 Increased mechanical properties for both 6xxx and 7xxx alloys 提升最终部件的耐腐蚀性能 Better corrosion resistance of the final componentUniqueSERVO HYDRAULIC PRESS BY AP&T 250 % higher performance -! 50 %

22、 lowe r energy consumpt ion-! Pro gressive dies Deep drawing Embossing案例分析-门内板Case study Door Inner门环的模拟 AA6016 热成形ThinnngThickening20.0%14.3%8.6%2.9%-2.9%-8.6%-14.3%-20.0%19.4%12.4%15.8%13.2%-22.5%-24.9%Simulation Door ring AA6016 - Hot FormingAA6016 150 mm/s forming speed:AA6016 375 mm/s forming s

23、peed:13.5%-17.5%17.0% 18.2%10.0%17.7%16.2%12.3%14.3%门环的模拟 AA6016 热成形Simulation Door ring AA6016 - Hot FormingTemperature C420411403394386377369360Higher tendency towards wrinkling due to low forming speed inhomogeneous temperature distribution occursHigher forming speed decreases wrinklingAA6016 150

24、 mm/s forming speed:AA6016 375 mm/s forming speed:Position of die:10 mm before forming is completed.零件重量的评估Evaluation of part weight Deep drawing steel: 181 MPa - YS AA6016 T6: 200 - 212 MPa - YS AA7075 T6: 480 MPa - 550 MPa - YSReduction of weight: 8.09 kgMaterialSteelAA6016AA7075Thickness1.5 mm1.5

25、 mm1.2 mmWeight11.2 kg3.89 kg3.11 kg总结Summary关键-在选取材料，产品设计，工艺研发方面的整体思维Key Holistic thinking with respect to material selection, product design and process development使用 w-termper和热成形时可使用f态或o态的材料- 更便宜的原材料F- and 0-temper material for Hot and W-temper Forming cheaper raw materialAluminum can be trimmed

26、 conventionally, compared to press hardened steel No Laser cutting is needed铝可以更快的加热和冷却-缩短周期时间Aluminum can take fast heating and cooling - short cycle times铝比钢更软压力需求变少-投资变少Aluminum is softer than steel less press force is needed less capital investment铝相比热成形钢，可以以传统的方式修剪无需激光切割多零件和功能集合的大零件减少装配Larger components with part and function and integration less assembly一次成形较少的模具投资Net shape forming less tooling invest高成形速度需求快速冲压High forming speed required