浦项汽车板EVI.doc

POSCOEVI ActivitiesAutomotive Steel Application Center Technical Research Laboratories POSCO Technical partnership with integrated solutionof steel and application technologyCustomerRequirements of material and partsAuto. steel production. Optimum specification. Quality controlPOSCOOptimum material and application technologyASAC. Material development. Part proposal9 Database of automotive steel products9 Development of integrated Solution and proposal9 EVI support based on SE & CE EVI (Early Vendor Involvement) Win-Win Strategy for Customer and POSCO From Styling to Mass ProductionStylingProto DesignProd. DesignCarMakersProcessTest CarManufact./TestProtoBuild 1 TestProtoBuild 2 TestPilotDie Design/Manufacture/TryoutEVI ActivityStyling FixMaterials Data, Forming Simulation, Materials Selection, Cost InformationMajor FixTesting & Evaluation, Materials-Process OptimizationMinor FixDie Development SupportSOPMaterialsInformationDetailed Properties for Part Manufacture, Test Materials SupplyMaterials QualityMonitoring StylingOEMPOSCOActivitiesPart designNozAvailable CADsystemCATIA V5UnigraphicsPro-engineerIGES format Part lists Part CAD dataMaterial Proposalz Material information Supply material information- Available material grades- Mechanical properties for crash, stiffness.- Welding conditions- Painting conditionsz Overview of feasibility Propose steel grade & thickness- Based on empirical guidelinesAcceptance ?Target weight & costTarget performance(Crash, Stiffness, NVH)- One step solver- Material DB Propose new forming technologies- TWB, HF, HPFYesReport & ProposalzAvailable one-step solverIn house s/wAutoformFastform Propose part design changes(optional) On HF & HPF, posco supplyStyling fixthe final productsOEMPOSCOActivitiesStyling fixYesDesign change ? Part lists Part CAD dataMaterial selectionzAvailable FE s/wPam-stampDynaformAbaqusz Detail of feasibility Forming simulations- Formability (crack, wrinkle)- Process & die design- Material change- Part modification Weldability- Spot, arc welding conditions Paintability- Electro deposition, phosphating adhesion, corrosion Design new forming technologies- TWB : Layout (Blank, welding line design), die surface design- HF : Part design for HF, costanalysis- HPF : Part design for HPF, cost analysisz Prototyping assist Sample supply Testing & evaluation Die development supportNoNoAcceptance ?YesReport & ProposalMajor fixOEMPOSCOActivitiesProto partsReportPart or assembly partPerformance evaluationz Performance Static/dynamic dentability Corrosion test Fatigue Stiffness Crashworthiness Performance evaluations were done by part or assembly partAppendix : Weight & Cost reduction AHSSz Model : Commercial vehiclez Proposed materialMaterialMild steelCHSP40ECHSP45EDP490DP590SPFH540TWBNo.54142412z Remark Weight reduction : 20% Cost reduction : 7%Part nameInitial designProposalRemarkMaterialThick nessMaterialThickne ssPANEL BODY SIDE INNER LH SLPR W/O WINDOWD513,SS:4010SPCC1.0DP5900.8Weight reductionPANEL BODY SIDE INNER RH SLPR W/O WINDOWD513,SS:4010SPCC1.0DP5900.8Weight reductionPANEL DOOR OUTER LH RHDIFHS400CHSP40E0.7DP4900.7Enhanced dent resistance TWB (Tailor Welded Blank)z Reinf. Side outer1.6t1.6t2.2t1.6t1.4t1.4t2.2t1.4t1.2t Production : 300,000 car / 5 yearsConventional (%)TWB (%)(+/-) %Panel costMaterial cost10076-24Tool cost10096-4Manufacturing cost100118+18Total cost10083-17Blank weight10078-22ConventionalTWB(+/-)Working expenseNo. Tools158-7 (ea)Press line saving-$ 7.5-$ 7.5Joining line saving-$ 1.1-$ 1.1z Door inner1.6t0.8t1.6t0.8t Production : 300,000 car / 5 yearsConventional (%)TWB (%)(+/-) %Panel costMaterial cost10092-8Tool cost10074-26Manufacturing cost10086-14Total cost10088-12Blank weight10092-8ConventionalTWB(+/-)Working expenseNo. Tools84-4 (ea)Press line saving-$ 2.2-$ 2.2Joining line saving-$ 0.3-$ 0.3 HF (Hydroforming)z Engine cradleProcessSequenceBending Press Preforming HydroformingProcess DesignBend Die(R=120mm)CAE SimulationDie CostsPart CostsWeight 60% 20% 30%No of parts : 6 1Weight : 15 8 Kgz Exhaust ManifoldNumber of individual partService Life Production cost Development time Weightconventional hydroforming productionseries production Schmitz&Brill, GermanyFatigue Analysis (Thermal Shock)10Hydroforming Part HPF (Hot Press Forming)z Bumper Impact Beam46147045314752345612471467460456Conventional designHPF designRemarkWeight (Kg)8.8625.543Weight reduction : 37.5%Penetration depth(mm)92.582.0Crash performance : + 11.4%11Main Activities in Automotive SteelApplication Center1.Material database2.Stamping3.Crashworthiness4.Welding5.Painting Material Data Base Material DataSpecification / Microstructure / Production ProcessTensile Test( Standard,High Strain Rate) / CrashworthinessFriction / FLD /Hole Expansion RatioSpot welding / Laser weldingLow Cycle Fatigue / High Cycle FatiguePre-treatment / Adhesion properties / Corrosion Support for Customers Experimentally evaluated material data are supplied Material data for simulations can be offered Feasible materials for each automotive part can be selectedPart design Propose the material selection- Flow curve, FLC, LDH,.- High strain rate flow curve (500/s)- Optimum welding and painting conditions Propose part geometry modificationsTool design Design the manufacturing process and tool concept Die face designForming simulationPerformanceEvaluation Forming simulation and design modification- Thinning, FLD, Stress & strain distribution- Load, BHF, Friction Springback analysis- Springback compensation design Evaluation of performance- Crashworthiness- Structural performance- Durability RequirementszMaterial : TRIP590, 1.2tzPart : Member dash outer lower ActivitieszDesign the drawing tool concept with the modifications Section A Modified modelPrevious model26 MMR 60BCA15zForming simulation with our materialzSpringback analysisThinningAUy, Uz = 0Ux, Uy, Uz= 0Uz = 016Activities - Crashworthiness Crash Test & SimulationPOSCO ActivitiesMaterialProperties Material properties for crashworthiness- High strain rate flow curve (500/s)- Failure load of a welded pointCrash Test Crash Test of auto-body members- Hat type structures- Front side member, Bumper beam- Evaluation of load & deformation distanceCrashSimulation Crash Analysis of auto-body members- Front side member, B-pillar, Bumper beam Crash Analysis of a full auto-body- NCAP, SINCAP, IIHS rear impact- Design modification with AHSS700 40600 35Displacement (mm)500 Assessment of crashworthinessAcceleration (G)30Assessment4003002001000252015105DisplacementAcceleration 0-5- Deformation mode- Crashing load, Energy Absorption- Velocity, Acceleration0 20 40 60 80 100 120Time (msec)17 Procedure of High Speed Tensile TestsDDQ0.003 /s1 /s10 /s100 /s500 /s600DynamicTensile SpecimenDynamicTensile Specimen500True Stress (MPa)400Material TestingApparatusMaterial TestingApparatus20010000.00 0.05 0.10 0.15 0.20 0.25True StrainHigh SpeedTensile TestsHigh SpeedTensile Tests600500True Stress (MPa)400Data ProcessingData ProcessingLoad35Displacement (mm)30201510503.53.02.0Load (kN)1.51.00.50.0500Engineering Stress (MPa)40030020000.001 /s10 /s500 /s3002001000.003 /s1 /s10 /s100 /s500 /s0.00.20.40.60.81.0Time (ms)0.0 0.1 0.2 0.3 0.4 0.5Engineering Strain00.00 0.05 0.10 0.15 0.20True StrainPiecewise Linear true stress-strain curves with strain rateInitial modelCrash TestCrashSimulationBumper model without hole(Impact velocity = 4.5 m/s)Bumper model with hole(Impact velocity = 4.5 m/s) Activities - Spot welding Weldability Lobe Static Strength16Material thickness : 1.2 mmElectrode force : 3.5 kNAHSS(590DP) HSLA(390R) Mild steel(DQ)Weld Time (cycles)Weld Strength (kN)20 12TSS CTSTSSAHSS154 5 6 7 8 9 10 11 12Weld Current (kA)10840DQ 390R 440R 590DP 590C 590TR 780DP 780TRGradeCTSWeld Size = 5t Electrode life of Zn-coated steels80006000 Automatic Welding SystemCoatedSteel40002000Electrode Life (welds)0EZGAEGGICoating weight MAG welding of Zn coated steelHGI 590DP, 2.3mm gaugeSingle side welded lap joint, Shielding gas : 80%Ar/ 20% CO2Recommend to change welding direction for decrease of pore defects in weldBackwardWelding directionPore by trapped Zn fumeForwardWelding direction Stretchability of laser weldsButt joint, 6kW CO2 LaserStretchability by LDH testStretchability = Dome height of weld/dome height of base metal80Welded material70Base material605040Height(mm)3020Dome101.41.2Stretchability1.00.80.60.40.20DP490DP590DP780TRIP590 TRIP7800.0Activities - Paintability Paintability testzPhosphating : Weight, Crystal shape/size, CoveragezED coating : Appearance (Pinhole voltage)zAdhesion Test : Cross cut, Water Resistance, Humidity Test, Impact Test, Erichsen cupping, Stone chippingzCorrosion Test Salt Spray Test (SST) : 480h, 1,000h Cyclic Corrosion Test (CCT) : VDA, SAE, ECC1 Large CCT cabinet : Assembled parts (e.g. door, hood etc) testPhosphating SimulatorCCT (Cycle Corrosion Tester)Corrosion Properties of Coated Steels4.03.53.02.52.01.51.00.5Delamination (mm)0.0CCTVDA mode, 10weeks10.08.06.04.02.0Delamination (mm)0.0SST1,000hDDQ GIDDQ GA340E GADDQ EG340E EGMaterialDDQ GIDDQ GA340E GADDQ EG340E EGMaterial10.0Correlation of CCT vs SSTDelamination SST (mm)8.06.04.02.00.00.00.51.01.52.02.53.03.54.0Delamination CCT (mm)New Forming Technology Activities1.TWB2.Hydroforming3.Hot Press Forming Activities - TWB Part design Propose the material selection- Grade, thickness- Mechanical properties of TWB Blank shape and weld line position Forming simulation and modificationPrototyping Manufacturing prototype of TWB- Laser cutting & welding Evaluation of TWB- Formability of laser welding (LDH)- Weldseam qualityManufacturePerformance evaluation Propose the die design concept Manufacturing TWB parts Evaluation of performance- Crashworthiness- Durability- Stiffness26 RequirementszMaterial : CHSP390, 1.8t + CHSP390, 3.0t (TWB)zPart : Floor side inner front end1.8t3.0t1.8t ActivitieszDesign the manufacturing processes & the drawing tool conceptBlankingBlankingEDDrawing(Open Draw)Drawing(Open Draw)CBTrimming/PiercingEADFlanging/(Flanging Up)Flanging/(Flanging Up)CBTrimming/PiercingCam FlangingCam Flanging27zForming simulation with our materialzPropose the modification of part geometries to consider the formabilityRHPart Corner ChamferProfile Line Change ( H = 2R ) Part development (Rear Suspension)Feasibility study-CAD from customer-Material property-Tube formability-Cost analysisPart design-Section analysis-Design modification238.8Process design-CAE analysis-Process parameter247.6 2462.1382.536.7239.2041.4242.9255.9255.8Proto tool design-Detailed designPrototyping-Tube making-Evaluation (shape, Thick.)HydroformedProduction tool making-Schuler, KWS (Germany)-Domestic tool maker Hydroforming parts developments Engine Cradle Rear Subframe Frame Cross Member Frame Side Rail Exhaust Manifold (Stainless Steel) Downpipe (Stainless