DUAL-PHASE STEEL APPLICATION FOR HIGH VENT BACKBONE WHEEL CONCEPTS
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1 DUAL-PHASE STEEL APPLICATION FOR HIGH VENT BACKBONE WHEEL CONCEPTS Presented by Tom Heck Hayes Lemmerz International Inc.
2 Agenda The High Vent Wheel Concept High Vent Products Concept Challenges Dual Phase Solution Summary
3 High Vent Wheel Products - The Concept The Concept: Offer a Steel Wheel and Trim System With Competitive Appearance to a Cast Aluminum Wheel.
4 High Vent Wheel Products - The Concept The Result: Multiple Stylings with a Single Tooled and Validated Steel Wheel.
5 High Vent Wheel Products - The Concept The Result: A Steel Wheel System Virtually Indistinguishable from a Cast Wheel at a Trimmed Steel Wheel Price.
6 High Vent Wheel Products - Benefits BENEFITS: 3D Styling with Trim Options Largest Windows of any Steel Wheel Spoked Cast Wheel Appearance Deep Spoke Appearance Without Weight Penalty Zero Draft Angle Appearance with Trim Euro-flange Appearance With Standard Weights Increased Geometry / Trim Flexibility Lower Initial / Replacement Costs Reduced Brake Temperatures Reduced Wheel Validation Costs/Timing
7 High Vent Wheel Products High Vent Wheel Products Kuhl Wheel Individual Spokes to Rim Riveted Attachment Struktur Wheel Full Ring Interface to Rim Welded Attachment
8 High Vent Wheel Products Kuhl Wheel Riveted Construction
9 High Vent Wheel Products Drop Well-Full Ring Construction (Struktur)
10 High Vent Wheel Products The Challenges THE CHALLENGES: Fatigue Strength Open Channel Spokes vs Toroidal Geometry Large Windows Formability Deep Channel Draw Deep Hub Draw Thinning in Critical Stress Locations Complex Window Pierce
11 High Vent Wheel Products Fatigue Strength and Formability Conventional Steel Wheel Toroidal Structure Struktur Steel Wheel Channel Structure
12 High Vent Wheel Products Fatigue Strength and Formability Channel Section Toroidal Radius Conventional Wheel Disc Section Struktur Wheel Disc Section
13 High Vent Wheel Products Fatigue Strength and Formability Varying Depth Channel Section Deep 3D Draw Location High Fatigue Stresses
14 High Vent Wheel Products Fatigue Strength
15 High Vent Wheel Products Fatigue Strength
16 High Vent Wheel Products Dual-Phase Steel Solution The Dual Phase Steel Solution Improved Fatigue Strength Improved Formability Typical Material for Wheels in Europe
17 High Vent Wheel Products Dual-Phase Steel Solution Dual Phase Attributes (DP550/600 vs SAE060YLF HSLA) Higher Fatigue Strength Higher Base Tensile Strength (87 ksi min. vs 75 ksi min.) Greater Work Hardening Paint Bake Hardening Formability Lower Yield to Tensile Ratio ( Typical vs )
18 Fatigue Life Comparison Initial DP Evaluation Conventional Wheels Average Rotary Life Comparison - Dual Phase Steel Saturn Drop Center Wheel Rotary Life Production - HSLA DP Supplier #1 DP Supplier #2 DP Supplier #3 DP Supplier #4 DP Supplier #5 DP Supplier #6 Dual Phase Supplier
19 Fatigue Life Comparison Fatigue Life Evaluation High Vent Wheels 16x7 5 Spoke Kuhl Wheel - Woehler Diagram Rotary Bending Test Rotary Moment (Nm) Rotary Life (Cycles) SAE060YLF HSLA Results Cycles DP600 Results - Supplier #5 Log. (SAE060YLF HSLA Results Cycles) Log. (DP600 Results - Supplier #5)
20 High Vent Wheel Products Dual-Phase Steel Solution Dual Phase Concerns Cosmetics Higher Si Chemistries ( Tiger Stripes ) (Require Low Si/High Cr Chemistry) Formability Higher Work Hardening (n-values) (Redesign Die Operations More Forming Up Front) Production Consistency DP Property Heat to Heat Variation Availability in North America of Low Si Version
21 High Vent Wheel Products Other Solutions Other Steel Solutions Stretch Flange (Bainitic Grade) Steel Trials Scheduled TRIP Steels
22 High Vent Wheel Products Summary Summary High Vent Steel Wheels Provide an Alternative to Cast Wheels Competitive Styling / Lower Cost (Removable or Permanent Trim) Reduced OEM Validation Testing Utilizes Current Manufacturing Equipment Provide a Market for Hot Rolled Dual Phase Steel
23 High Vent Wheel Products - Acknowledgements I d Like to Acknowledge the Following Contributors: Steel Companies: National Steel US Steel Kobe Usinor Usiminas Personnel: Al Coleman (Hayes Lemmerz) Mike Miller (Hayes Lemmerz) Hayes Lemmerz Sedalia, MO Plant Chuck Gregoire (National Steel) Wei Ping Sun (National Steel)
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