高強(qiáng)度鋁成形技術(shù)多功能生產(chǎn)線

1、高強(qiáng)度鋁成形技術(shù)多功能生產(chǎn)線技術(shù)創(chuàng)新，變革未來高強(qiáng)度鋁成形技術(shù)多功能生產(chǎn)線Multipurpose production line for high strength Aluminium forming technologies來自AP&T 的熱成形技術(shù)AP&Ts HForm Technology專注于汽車行業(yè)，改變的驅(qū)動力來自于CO2 排放法規(guī)Focusing on automotive, the key driver for change is the CO2 emission regulation滾動阻力Rolling resistance氣動阻力Aerodynamic resistan

2、ce車身重量Vehicle weight傳動系統(tǒng)Drivetrain輕量化設(shè)計Design to lightweight新材料和工藝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 輕量車身是關(guān)鍵A light weight Car Body is keyEnergy efficiencyLightweightSafetyOUR FOCUS汽車高強(qiáng)度材

4、料之旅才剛開始The journey of high strength materials in cars, has just begun.為什么不是高強(qiáng)度鋁板的壓力硬化Why not press harden high strength Aluminium?為什么需要在高溫下成形，如7系鋁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高強(qiáng)度鋁成形的車身

6、部件制造PRODUCTION OF BODY COMPONENTS FROM HIGH-STRENGTH ALUMINUM 輕量化 Lightweight 高強(qiáng)度 High strength 復(fù)雜零件成形-新機(jī)遇 Complex shape new opportunities工藝路線的配置 AP&T的熱成形工藝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 的高強(qiáng)度鋁之旅AP&Ts journey on high strength AluminiumAP&TLOCOLITECUP TOOLPRODUCTIONEWILOCOMATECH TOOLLOTUSTESTLINE CIPCOPROJECTFIATTEST ”HAT PROFILE”20132014201520162017PABLOCOLITETESTALVABBQFORMINGLOCOMATECHFIATPROCESESSPROJECTPROJECTSIMULATION20172

9、014201520162013故事是怎樣開始的？2013年3月Blidsberg測試中心鋁熱成形測試How did the Aluminium story start? Aluminium hot forming tests at AP&Ts test centre in Blidsberg 03/20137系鋁邁出的第一步First steps towards 7000 alloys 6082 and 7075 Courtesy of Fiat and LotusAP&TLOCOLITECUP TOOLPRODUCTIONEWILOCOMATECH TOOLLOTUSTESTLINE CIP

10、COPROJECTFIATTEST ”HAT PROFILE”20132014201520162017PABLOCOLITETESTALVABBQFORMINGLOCOMATECHFIATPROCESESSPROJECTPROJECTSIMULATION20172014201520162013第一個鋁熱成形的模擬計算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 研發(fā)中心AA6082 門內(nèi)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挑戰(zhàn) 磨損/擦傷Challenge - Wear / Galling 擦傷是磨損的一種形式，由滑塊表面之間的粘合造成Galling is a form of wear caused by adhesion between sliding surfaces 擦傷導(dǎo)致表面的高粗糙度Galling causes

13、 a high surface roughness 表面高粗糙度導(dǎo)致高摩擦A high surface roughness leads to high friction 高摩擦導(dǎo)致材料失效和較差的成形部件表面質(zhì)量High friction leads to material failure and low surface quality of the formed partGalling needs to be prevented!Source: University of Erlangen挑戰(zhàn) 磨損/擦傷未涂層Uncoated不合適的潤滑劑Unsuitable Lubricant涂層Coat

14、ed合適的潤滑劑Suitable LubricantAP&T B-Pillar:Challenge - Wear / Galling 我們發(fā)現(xiàn)了正確的模具涂層和潤滑劑We found the right tool coating and lubricationCup tool:GallingGallingGalling未涂層Uncoated不合適的潤滑劑Unsuitable LubricantNo Galling涂層Coated合適的潤滑劑 Suitable LubricantAP&TLOCOLITECUP TOOLPRODUCTIONEWILOCOMATECH TOOLLOTUSTESTLI

15、NE CIPCOPROJECTFIATTEST ”HAT PROFILE”20132014201520162017PABLOCOLITETESTALVABBQFORMINGLOCOMATECHFIATPROCESESSPROJECTPROJECTSIMULATION20172016201520132014工藝研究： 高強(qiáng)度鋁的成形Process study: Forming of High Strength Aluminium AA7075 T6 1.2 mm 增加設(shè)計空間Increases freedom of design 確保功能整合Enables function integratio

16、n 確保最終成形Enables net shape forming如何考慮高強(qiáng)度鋁？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% 減少細(xì)節(jié)數(shù)量 Reduces the number of details 減少模具數(shù)量 Reduces the number of tools 更有效的搬運(yùn)，物流和裝配 More efficient handling, logistics and assemblyAP&TLOCO

18、LITECUP TOOLPRODUCTIONEWILOCOMATECH TOOLLOTUSTESTLINE CIPCOPROJECTFIATTEST ”HAT PROFILE”20132014201520162017PABLOCOLITETESTALVABBQFORMINGLOCOMATECHFIATPROCESESSPROJECTPROJECTSIMULATION20162017201520132014 熱成形hot forming w-temper 溫成形warm forming 鋁(6000 and 7000)aluminum (6000 and 7000)鋁熱成形概念介紹Introdu

19、cing the HForm concept鋁的多層箱式爐新的加熱概念A(yù)luminum MLFNew heating concept快速加熱Fast heating強(qiáng)化固溶Solutionizing潤滑/未潤滑板料Lubricated / Non lubricated sheets安全定位Safe Positioning內(nèi)部無移動部件No moving parts inside緊湊型設(shè)計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傘預(yù)冷工藝Intermediate Cooling 降低節(jié)拍時間Cycle time reduction 改善摩擦條件Im

21、proved tribological condition 中等溫度提高成形性 Increased formability at the intermediate temperature 提升6系和7系的機(jī)械性能 Increased mechanical properties for both 6xxx and 7xxx alloys 提升最終部件的耐腐蝕性能 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-門內(nèi)板Case study Door Inner門環(huán)的模擬 AA6016 熱成形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%門環(huán)的模擬 AA6016 熱成形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.零件重量的評估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總結(jié)Summary關(guān)鍵-在選取材料，產(chǎn)品設(shè)計，工藝研發(fā)方面的整體思維Key Holistic thinking with respect to material selection, product design and process development使用 w-termper和熱成形時可使用f態(tài)或o態(tài)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鋁可以更快的加熱和冷卻-縮短周期時間Aluminum can take fast heating and cooling - short cycle times鋁比鋼更軟壓力需求變少-投資變少Aluminum is softer than steel less press force is needed less capital investment鋁相比熱成形鋼，可以以傳統(tǒng)的方式修剪無需激光切割多零件和功能集合的大零件減少裝配Larger components with part and function and integration less assembly一次成形較少的模具投資Net shape forming less tooling invest高成形速度需求快速沖壓High forming speed required