REVIEW OF HOT FORMING TECHNIQUE USED IN AUTOMOTIVE INDUSTRY

Yıl 2015, Cilt: 56 Sayı: 660, 41 - 51, 19.02.2015

Recep Muhammet Görgülüarslan Mehmet Ali Güler

Öz

New requirements in automotive industry demand lighter components with higher strength. In the last years, sheet metal forming processes at elevated temperatures have gained much importance due to the possibility of producing components with enhanced strength and geometrical accuracy and reduced mass. Finite element method is used in order to determine the formability of the component and perform the correct design of the tools before hot forming process. In this study, hot forming process and finite element analysis of hot forming simulations of high strength steels are reviewed with all steps from heating to cooling. Then, finite element model of a U channel profile with high strength steel material is performed and hot forming and cold forming processes are simulated and the results are compared. Thus, it is aimed that hot forming process has many advantages in order to produce structural components with high strength in automotive industry and usage of this process should be increased.

Anahtar Kelimeler

Hot metal forming, finite element method

OTOMOTİV ENDÜSTRİSİNDE KULLANILAN SICAK ŞEKİLLENDİRME TEKNİĞİNİN İNCELENMESİ

Öz

Otomotiv sanayindeki yeni gereksinimler, otomobillerin yüksek dayanımlı fakat daha hafif parçalar ile üretilmesini gerektirmektedir. Son zamanlarda yaygınlaşmaya başlayan ve yüksek mukavemetli çelikler kullanılan ve östenitleşme sıcaklığının üzerinde bir sıcaklıkta gerçekleştirilen sıcak şekillendirme işlemi, son derece dayanıklı, daha hafif ve doğru geometriye sahip parçaların üretilebilmesi sayesinde çok kullanışlı hale gelmiştir. Sıcak şekillendirme işlemi öncesi, parçanın şekillendirme analizinin yapılması, parçanın üretilebilirliğinin ve işlem sonuçlarının önceden görülebilmesi açısından sonlu elemanlar yöntemi kullanılmaktadır. Bu çalışmada, sıcak şekillendirme işlemindeki sac metalin ısıtılması işleminden metalin şekillendirilmesine, soğutulmasına ve sonraki işlemlere kadar tüm süreç açıklanmış ve sonlu elemanlar yöntemi ile yüksek mukavemetli çeliklerin sıcak şekillendirme süreci incelenmiştir. Ardından, yüksek mukavemetli çelik malzemeli U tünel profil parçanın sıcak ve soğuk şekillendirme simülasyonları gerçekleştirilerek sonuçlar incelenmiştir. Bu çalışma, sıcak şekillendirme işleminin otomotiv sektöründe yüksek dayanımlı yapısal parçaların üretimi için uygun olduğunun ve kullanımının yaygınlaştırılması gerektiğinin anlaşılmasını hedeflemektedir.

Anahtar Kelimeler

Sıcak metal şekillendirme, sonlu elemanlar yöntemi

Kaynakça

• 1. Turetta, A., Fanini, S., Ghiotti, A., Bruschi, S. 2008. “Calibration of Numerical Simulation for Hot Stamping,” 7th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, 1-5 September 2008, Zurich.
• 2. Behrens, B.– Olle, A., Schaffner, C. P. 2008. “Process Simulation of Hot Stamping in Consideration of Transformation-induced Stresses,” 7th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, 1-5 September 2008, Zurich.
• 3. Lee, M. G., Kim, S. J., Han, H. N. 2009. “Finite Element Investigations for the Role of Transformation Plasticity on Springback in Hot Press Forming Process,” Computational Materials Science, vol. 47, issue 2, p. 556-567.
• 4. Griesbach, B., Oberpriller, B. 2008. “Simulation in Tool and Die Shop,” 7th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, 1-5 September 2008, Zurich.
• 5. Son, H. S., Kim, H. G., Cho, Y. R. 2008. “Formability Evaluation for Hot Press Formed Part Using Couple Thermo-Mechanical Analysis,” 7th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, 1-5 September 2008, Zurich.
• 6. Bergman, G., Oldenburg, M. 2004. “A Finite Element Model for Thermomechanical Analysis of Sheet Metal Forming,” International Journal for Numerical Methods in Engineering, vol. 59, issue 9, p. 1167-1186.
• 7. Tekkaya, A. E., Karbasian, H., Homberg, W., Kleiner, M. 2007. “Thermo-mechanical Coupled Simulation of Hot Stamping Components for Process Design,” Production Engineering, vol. 1, issue 1, p. 85-89.
• 8. Lee, M. G., Kim, S. J., Han, H. N., Jeong, W. C. 2009. “Application of Hot Press Forming Process to Manufacture an Automotive Part and its Finite Element Analysis Considering Phase Transformation Plasticity,” International Journal of Mechanical Sciences, vol. 51, issue 11, p. 888-898.
• 9. Kerausch M., Schönbach, T. 2008. “Design of Hotforming Processes based on Sensitivity Analysis of Process Parameters,” 7th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, 1-5 September 2008, Zurich.
• 10. Callister Jr, W. D. 2001. Fundamentals of Materials Science and Engineering, John Wiley & Sons, New York, USA.
• 11. Akerström, P., Oldenburg, M. 2008. “Numerical Simulation of a Thermo-Mechanical Sheet Metal Forming Experiment,” 7th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, 1-5 September 2008, Zurich.
• 12. Altan, T. 2007. “Hot-stamping Boron-alloyed Steels for Automotive Parts,” Stamping Journal, vol. 19, issue 2, p. 41-42.
• 13. Neugebauer, R., Altan, T., Geiger, M., Kleiner, M., Sterzing, A. 2006. “Sheet Metal Forming at Elevated Temperatures,” CIRP Annals-Manufacturing Technology, vol. 55, issue 2, p. 793-816.
• 14. Karbasian, H., Tekkaya, A. E. 2010. “A Review on Hot Stamping,” Journal of Materials Processing Technology, vol. 210, issue 15, p. 2103-2118.
• 15. Mori, K., Maki, S., Tanaka, Y. 2005. “Warm and Hot Stamping of Ultra High Tensile Strength Steel Sheets Using Resistance Heating,” CIRP Annals-Manufacturing Technology, vol. 54, issue 1, p. 209-212.
• 16. Karbasian, H., Klimmek, C., Brosius, A., Tekkaya, A. E. 2008. “Identification of Thermo-Mechanical Interaction During Hot Stamping by Means of Design od Experiments for Numerical Process Design,” 7th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, 1-5 September 2008, Zurich.
• 17. Bariani, P. F., Bruschi, S., Ghiotti, A., Turetta, A. 2008. “Testing Formability in the Hot Stamping of HSS,” CIRP Annals-Manufacturing Technology, vol. 57, issue 1, p. 265-268.
• 18. Roll, K. 2008. “Simulation of Sheet Metal Forming-Necessary Developments in the Future,” 7th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, 1-5 September 2008, Zurich.
• 19. Lorenz, D., Haufe, A. 2008. “Recent Advances and New Developments in Hot Forming Simulation with LS-DYNA,” 7th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, 1-5 September 2008, Zurich.
• 20. Olsson, T. 2009. “An LS-DYNA Material Model for Simulations of Hot Stamping Processes of Ultra High Strength Steels,” 7th European LS-DYNA Conference, 14-15 May 2009, Salzburg.
• 21. Shapiro, A. B. 2007. “Using LS-DYNA for Hot Forming,” 6th German LS-DYNA Forum, 11-12 October 2007, Frankenthal.
• 22. Shapiro, A. B. 2009. “Using LS-DYNA for Hot Stamping,” 7th European LS-DYNA Conference, 14-15 May 2009, Salzburg.
• 23. Shapiro, A. B. 2006. “LS-DYNA Features for Hot Stamping,” 9th International LS-DYNA Users Conference, 4-6 June 2006, Detroit.