CPF Center for Precision Forming ( Taylan Altan, Director ( A short Review July, 2011

CPF The Ohio State University (OSU) and have established the Industry/University Cooperative Research Center (I/UCRC) on Precision Forming (CPF) focusing on research needs of metal forming industry. Funding is provided by National Science Foundation (NSF) and member companies. CPF ( benefits from research conducted at Engineering Research Center for Net Shape Manufacturing (ERC/NSM – Introduction 2

CPF Objectives Improve existing metal forming processes/products and develop new innovative processes, tooling and equipment. Conduct projects in close collaboration with industry and transfer the results to the member companies. Train and educate engineers in the fundamentals and practice of metal forming science and technology. 3

CPF Current Members Aida- America Corp. Boeing EWI Honda ESI North America General Motors Corp. Interlaken Technology Corp. POSCO (Korea) IM Steel Scientific Forming Technologies (SFTC) Corp. IMRA America Metalsa JCI Thixomat Tyco Labein Cincinatti, Inc 4

CPF CPF 1.1: Elevated temperature stamping and hydroforming of Al, Mg and Stainless Steel Objective: Develop guidelines for elevated temperature sheet forming (process optimization, lubricant evaluation and Finite Element Modeling) Warm deep drawing (in cooperation with AIDA Engineering, Ltd.) Current Projects 5

CPF CPF 1.4: Investigation of springback in forming Advanced/High Strength Steel (A/HSS) Objectives:  Determine the variation of Young’s Modulus with deformation /strain  Predict and reduce springback in stamping A/HSS Planned experiments (Tool concept) 1. Straight flanging 2. Stretch flanging 3. Shrink flanging 4. Straight hat shape drawing and stretching 5. Curved hat shape drawing and stretching Current Projects 6

CPF CPF- 2.1: Determination of room temperature properties of Al and steel sheet materials under biaxial conditions Develop a standardized tool design and procedure to determine flow stress, anisotropy and formability under biaxial deformation Objective: Sheet bulge test (Viscous Pressure Forming –VPF) Current Projects 7

CPF Hole Modified Limiting Dome Height (MLDH) Test Formed sample (OD = 14in, t 0 = 0.034in) CPF- 2.2: Determination of flow stress of Al and Mg sheet materials at elevated temperatures Objective: Determine flow stress of sheet materials at elevated temperatures for the warm forming process. Inverse Analysis Technique Current Projects 8

CPF CPF- 2.3: Investigation of tribological conditions in forming uncoated and galvanized Advanced/Ultra High Strength Steels (A/UHSS) Determine the effect of process parameters (interface temperature, pressure and relative sliding speed) on galling / reduce galling Determine the effect of process parameters (interface temperature, pressure and relative sliding speed) on galling / reduce galling Objective: Twist compression Test (TCT) Current Projects T P A rmrm Testing materials: DP 600 Bare with Lub A Testing conditions: P = 170 MPa & N= 8.9 RPM Tool surface Galling Micrograph of galled surface 9 (in cooperation with IRMCO)

CPF CPF - 4.1: Multi Point Control (MPC) die cushion and blank holder technology in stamping Objective: Develop an automated system to optimize the Blank Holder Force for robust stamping Proposed system for robust stamping using MPC Current Projects Die Blank holder / Binder Individual hydraulic cylinders for each cushion pin (Source: Müller Weingarten) Location of cushion pins/ cylinders in the die (continue) 10

CPF Parts formed with OSU software by USCAR (try-out reduced from 3 days to 3 hours) Current Projects Al 6111-t4 (t = 1 mm)BH210 (t = 0.81 mm)DP500 (t = 0.78 mm) CPF - 4.1: Multi Point Control (MPC) die cushion and blank holder technology in stamping (continue) Sample parts [GM lift gate inner panel] with different materials and sheet thickness was formed in the same die by simply adjusting the BHF. 11

CPF CPF- 4.2: Applications of Tube Hydroforming (THF) Technologies Objective: Utilize past R&D experience at OSU to assist interested companies in introducing and/or improving the hydroforming technology Current Projects 12 General concept of Tube Hydroforming Process (Hydroforming of the T-shape part) A. B. C. D. [Leitloff, 1997 ]

CPF New tasks under consideration Cold and Warm Hydroforming of Al and Mg alloys Simulation of Hot Stamping of Boron Steels Precision /Flashless Forging of automotive components (for example tie rods, pinion gears and bevel gears) Prediction and reduction of residual stresses in machining and burnishing (advanced FE analysis) Micro-stamping for electronic applications (lead frames, CD drive components, etc.) Center for Precision Forming (CP-Forming- 13