w w w. a u t o s t e e l. o r g

Transcription

1 Great Designs in Steel is Sponsored by: AK Steel Corporation, ArcelorMittal Dofasco, ArcelorMittal USA, Nucor Corporation, Severstal North America and United States Steel Corporation

2 Tailor Welded Coils: Applications, Results & Body Structure Impact Mark Eisenmenger TWB Company LLC

3 Agenda Review Tailor Welded Blank Applications Evolution of Tailor Welded Blanks to Tailor Welded Coils Application and Results of Tailor Welded Coils BIW Impact with Tailor Welded Coils

4 Tailored Product Benefits General Product Benefits Part Reduction/Integration Mass/Weight Savings Improve Functionality Manufacturing Benefits Reduce Manufacturing Complexity Improve Dimensional Control Cost Benefit Lower Tooling & Labor Reduce Number of Operations Less Material Handling & Enhanced Logistics Material Cost Reduction (MCR) Improved Material Utilization Nesting Scrap Reduction Optimize Steel Properties Throughout the Part

5 Tailor Welded Blank Applications There are 18 common tailor welded blank automotive applications

6 Welding Process Butt Weld (no filler) Continuous Flow Welding process Gauge Possibilities: 0.4mm to 3.5mm Weld Lengths up to 4 meters Material Combinations Include: Stainless CR, HR, Zn Coated, DP, TRIP,CP and boron grades Each weld is computer monitored and serialized

7 Quality Monitoring TWB utilizes: Online Weld profile monitoring Magnetic Flux Leakage Detection (MFL) Sampling Cross sectional analysis Visual inspection Result: Six Sigma Quality Levels (External PPM 3 or less!)

8 Tailor Welded Coils: A Breakthrough Process Tailor welded coils provide specific product benefits: Exact grade, coating and gage of steel where it is needed. Cost reduction with part consolidation. Lighter weight and improved part performance. Tailored products in coil fed products such as progressive die and roll-forming.

9 Tailor Welded Coils: Process Overview Continuous process that consists of: Monitoring & Reporting Un-coiling / Leveling Welding Re-coiling

10 Tailor Welded Coils: Quality Monitoring Utilize the same quality criteria for tailor welded blanks and tailor welded coils Weld defects are identified and mapped for each coil The result is improved material utilization with minimal material loss Coil Map

11 Tailor Welded Coils: Coil Map Example Weld defects are identified and mapped for each coil with customer specified methods Typical methods include: Punched hole, Ink jet, Metered report Weld Defect Punch Punched Hole Ink Jet

12 Tailor Welded Coils: Production Machine

13 Progressive Die TWC Applications There are more than 35 potential tailor welded coil automotive applications

14 Potential Applications for TWC Seat tracks, supports and seat frames Door intrusion beams Door belt reinforcement Roof headers and rails Roof cross rails Plenum floor Bumper beams Sills Floor pan strainer Chassis components Rail back plates Sun roof reinforcements Door beam

15 Progressive Die Operation Coil fed operations with tailored steel enable: lower die & assembly investment material savings part weight savings improved part performance improved dimensional control Tailored Coil Finished Part

16 Progressive Stamping TWC Parts Longitudinal Chassis Beam Saves 2.0 pounds / vehicle Saves $1.50 / vehicle 2 parts / vehicle In production (Germany)

17 Progressive Stamping TWC Parts Roof Cross Member Integrates 3 stampings into 1 Improved roof crush and side impact results Saves.8 lbs / vehicle Saves $1.60 / vehicle In production (Germany) 1.35 mm 1.0 mm 1.35 mm

18 Progressive Stamping TWC Parts Roof Bow Integrates 3 stampings into 1 Improved roof crush and side impact results Saves 2.0 lbs / vehicle Saves $2.25 / vehicle Proposed (USA) 1.0 mm 1.8 mm 1.8 mm Part developed by.dwg Design Services

19 Progressive Stamping TWC Parts Heat Shield Assembly 2.3 mm 0.7 mm 0.7 mm Improves part stiffness Consolidates 2 stampings into 1 Eliminates assembly Stainless steel 439 Saves.25 lbs / part Saves $.95 / vehicle Proposed (USA) Part developed by.dwg Design Services

20 Progressive Stamping TWC Parts 1.0 mm Seat Side Member 2.1 mm Saves 2.0 lbs / vehicle (4 parts / vehicle) Costs $.60 / vehicle Proposed (USA) Part developed by.dwg Design Services

21 Progressive Stamping TWC Parts Appliance Mounting Bracket 1.7 mm 1.3 mm 1.0 mm Integrates 2 stampings into 1 Improves interface stiffness Saves.3 lbs / appliance Saves $.45 / appliance Proposed (USA) Part developed by.dwg Design Services

22 Progressive Stamping TWC Parts 1.2 mm Muffler Shell 0.7 mm Austenitic Stainless Steel Saves 1.0 lb / vehicle Saves $1.42 / vehicle In production (Germany) 1.2 mm

23 Transfer Press Stamping TWC Parts Reinf. Compt RR S/Rail Coil Feed Finished Part Cut Draw Trim Pierce Cam Pierce Flange Re-strike 2000 Ton Transfer Press 580 MPa 1.2 mm / 780 MPa 1.1 mm

24 Part Consolidation Savings Example (2) parts are designed and stamped as progressive die and assembled Parts are consolidated as a tailor welded blank and stamped in a transfer press Parts are consolidated as a tailor welded coil and stamped in a progressive die Investment: $575K Piece Cost: $7.20 Weight: 3.62kg Baseline Investment: $395K Piece Cost: $6.69 Weight: 3.40kg Improves: Investment: 31% Piece Cost: 7% Weight: 6% Investment: $345K Piece Cost: $4.97 Weight: 3.40kg Improves: Investment: 40% Piece Cost: 31% Weight: 6%

25 Progressive Die Potential TWC Impact Optimizing 33 parts tailor welded coil applications Upper Body Front End Under Body

26 Potential Impact to BIW Structure Upper Body (10 applications) 6.5 kg of weight savings Provides the best cost / weight savings ratio Front End (6 applications) 4.4 kg of weight savings Provides the highest percentage of weight savings Under Body (17 applications) 12.8 kg of weight savings Provides the highest number of applications 25 kg of potential weight savings with TWC in BIW

27 Key Advantages for TWC Many parts have a calculated 25% stamping cost savings with the benefit of weight savings Lower die investment costs Potential to convert to more efficient press lines: tandem press to transfer press transfer press to progressive press lines

28 Summary: A Cost Effective Materials Approach Tailored Coils bring tailor welded blank benefits to progressive die, coil fed stamping processes and roll-forming applications Tailored products achieve cost effective weight savings to your programs

29 Thank you!

30 Great Designs in Steel is Sponsored by: AK Steel Corporation, ArcelorMittal Dofasco, ArcelorMittal USA, Nucor Corporation, Severstal North America and United States Steel Corporation