NEXT GENERATION FORCE SOLUTIONS FOR FORMING HIGH STRENGTH STEELS

Transcription

1 NEXT GENERATION FORCE SOLUTIONS FOR FORMING HIGH STRENGTH STEELS Darrell Quander Jr. Hyson

2 INTRODUCTION Common Goals Reduce our environmental footprint Better fuel efficiency Lighter cars Increase safety ratings Stronger Cars - Stronger materials Lighter Vehicles Better Fuel Economy (over 50mpg) Stronger Vehicles Safer Crash Ratings and Safety

3 COMMON FORMING STRUGGLES Forming Pains Quality Wrinkling Tearing Cracking Springback Part inversion Limited Force due to current force solutions Binder holding force Draw force Productivity More draw stations Quality Inconsistency in steel batches Materials having different properties and characteristics Press Wear Reverse tonnage Initial contact shock Gear and clutch rebuild

4 COMMON FORMING STRUGGLES MILL Rolling Material Testing New Material T&D Try out of new materials Dies robust to handle new characteristics STAMPING Higher tonnage More Controllability

5 BUSINESS SEGMENTS FORCE CONTROL

6 CUSHION COMPARISON Characteristics Air Nitrogen Servo- Controlled Force Maintenance Flexibility Controllability Programmability Initial Cost Lifetime Cost Fair Good Best Fair Best Good Fair Fair Best Fair Fair Best Fair Fair Best Best Best Fair Fair Good Best

7 SERVO-CONTROLLED CUSHION Cushion (Stud mounted to bottom of bolster) Servo Valve and Manifold

8 Mechanical, Hydraulic, Servo Press Compatible Completely controllable force Adjustable force dynamically Delay at bottom dead center Reverse forming Part ejection Multiple zones of force Programmability- Electronics and feedback SERVO-CONTROLLED CUSHION

9 Mechanical, Hydraulic, Servo Press Compatible Completely controllable force Adjustable force dynamically Delay at bottom dead center Reverse forming Part ejection Multiple zones of force Programmability- Electronics and feedback SERVO-CONTROLLED CUSHION

10 Mechanical, Hydraulic, Servo Press Compatible Completely controllable force Adjustable force dynamically Delay at bottom dead center Reverse forming Part ejection Multiple zones of force Programmability- Electronics and feedback SERVO-CONTROLLED CUSHION

11 Mechanical, Hydraulic, Servo Press Compatible Completely controllable force Adjustable force dynamically Delay at bottom dead center Reverse forming Part ejection Multiple zones of force Programmability- Electronics and feedback SERVO-CONTROLLED CUSHION

12 Mechanical, Hydraulic, Servo Press Compatible Completely controllable force Adjustable force dynamically Delay at bottom dead center Reverse forming Part ejection Multiple zones of force Programmability- Electronics and feedback SERVO-CONTROLLED CUSHION Typical cushion force curve BDC Cushion force curve w/ Reverse Tonnage BDC

13 Mechanical, Hydraulic, Servo Press Compatible Completely controllable force Adjustable force dynamically Delay at bottom dead center Reverse forming Part ejection Multiple zones of force Programmability- Electronics and feedback SERVO-CONTROLLED CUSHION

14 Mechanical, Hydraulic, Servo Press Compatible Completely controllable force Adjustable force dynamically Delay at bottom dead center Reverse forming Part ejection Multiple zones of force Programmability- Electronics and feedback SERVO-CONTROLLED CUSHION Cushion force curve w/ Part Ejection BDC

15 Mechanical, Hydraulic, Servo Press Compatible Completely controllable force Adjustable force dynamically Delay at bottom dead center Reverse forming Part ejection Multiple zones of force Programmability- Electronics and feedback SERVO-CONTROLLED CUSHION

16 Mechanical, Hydraulic, Servo Press Compatible Completely controllable force Adjustable force dynamically Delay at bottom dead center Reverse forming Part ejection Multiple zones of force Programmability- Electronics and feedback SERVO-CONTROLLED CUSHION

17 Mechanical, Hydraulic, Servo Press Compatible Completely controllable force Adjustable force dynamically Delay at bottom dead center Reverse forming Part ejection Multiple zones of force Programmability- Electronics and feedback SERVO-CONTROLLED CUSHION

18 FORMING SOLUTIONS Forming Pains Quality Wrinkling Tearing Cracking Springback Part inversion Limited Force due to current force solutions Binder holding force Draw force Productivity More draw station Inconsistency in steel batches Materials having different properties and characteristics Press Wear Reverse tonnage Initial contact shock Gear and clutch rebuild Forming Solutions Increase part quality by enabling user to control force at specific points in stroke Quality Increased force and press capacity to secure jobs requiring higher tonnage Decrease draw stations with precise, dynamic force throughout stroke Inconsistencies in steel batches are compensated for with controlled flexibility and change parameters forming better quality products Pre acceleration and reduced initial force eliminates shock load seen at cushion contact. By delaying at bottom dead center you can eliminate reverse tonnage into the press which can reduce press wear.

19 Steel Mills R&D Lab press CONCLUSION Test and prove out the formability new grade steels before it enters the market to the OEMs Die shops Try out press Gives them more force to form new age material, and reduces set up times by having the flexibility Stampers Production Press Whether your upgrading press or purchasing a new one servo controlled cushions gives the controllability to form better quality parts in less stations

20 CONCLUSION Working with Advanced High Strength Steels is an opportunity to be creative What are you doing in your process to advance the formability of high Strength Steels in your facility?

21 CONTACT Darrell Quander Jr. Hyson Press Solutions