1. National Institute of Standards and Technology (NIST) Advanced Manufacturing Technology Consortia (AMTech) Program Award Number: 70NANB14H056
Development of Roadmap and Consortium for Innovation in Sheet Metal Forming
Challenge
Code Tier 2 Project Titles
3.4 Closed-Loop Control of Deep Drawing Process Using Servo-Controlled Press
2.5 Plane Stress Fracture Prediction for Aluminum and High Strength Steel Sheets
3.5 Method of Manufacturing Ultra-High Strength Steel Sheet Part

2. 3.5 Method of Manufacturing Ultra-High Strength Steel Sheet Part
Objective: Develop a set of methods that can be used to manufacture ultra-high strength steel sheet B-plr & Deep Channel like part.
Technical Benefits:
Enable to use ultra-high strength steel sheet for most structural stamping application.
UNH - 28 October 2016
Sheet Metal Forming

3. 3.5 Method of Manufacturing Ultra-High Strength Steel Sheet Part
Approaches:
Experimental draw, Trim/Pierce, and Flange/Restrike die Scale): Design, Build, Trails, Measurement and analysis
Processes: double action, with/without pad, variable Ram motion control, variable binder force control
Simulation modeling validations: material modeling, lubrication Modeling, temperatures’ effects
Die material and coating effects validation
Proposed Scaled Part: Combination of B-Plr and Shot Gun +
Springback: Side-Wall- Curl & Twisting
Springback: Side-Wall- Curl & Twisting
Stretch-Bend Fracture?
UNH - 28 October 2016
Sheet Metal Forming

4. 3.5 Method of Manufacturing Ultra-High Strength Steel Sheet Part
Technical Obstacles:
Formability (Virtual Predictability Validations are needed)
Local Formability (Edge Cracking, Stretch-Bending with R/T<5, material fracturing near necking strain): Difficult to predict using Shell Elements directly. Criteria and empirical guideline are needed, and fracture models may help.
Springback control (Virtual Predictability Validations are needed)
Virtual Compensation: General stamping (R/T<5), Consistent Material properties
Side Wall-Curl mode: Post-Stretch/Compression (Steak Bead; Stingers/formations on Binder; Compression before the end of stroke).
Twisting Mode: Balanced twist moment by binder restraining conditions…
Sheet Material inconsistency, variable friction response: Lubrication, Temperature….
Lubrications: Temperature effects, CAE Modeling
Long tool/die life (Experimental confirmations are needed)
Die Materials optimization: Draw-die, Trim/Piercing Die, Restrike / Flanging Die
Die Coating, Treatment: PVD, Nitriding, Surface Roughness
Non Technical Obstacles:
Material inconsistency: thickness, properties
Material anisotropy
Lubrication condition uncertainty
Press and die deflection
cost: $500K
Die Design and Build: $260K, Try-outs Trials and Stamping made: $100K; Measurement and Analysis: $30K; Material Testing: $30K; Simulation modeling and Validation: $80K
Time: 24 Months
UNH - 28 October 2016
Sheet Metal Forming

5. 3.5 Method of Manufacturing Ultra-High Strength Steel Sheet Part
Path to Implementation:
Lab scale validations: Experimental die.
NAFTA Steel, OEMs, Universities cooperation
Full scale validation: B-Plr
NAFTA Steel, OEMs Universities cooperation
UNH - 28 October 2016
Sheet Metal Forming

6. 3.5 Method of Manufacturing Ultra-High Strength Steel Sheet Part
Discussion:
Anything missing for active industry support?
Estimated benefits realistic & complete?
Technical and non-technical obstacles complete or over reaching?
Alternative implementation paths or better approaches?
Conflicts with intellectual property or trade secrets?
UNH - 28 October 2016
Sheet Metal Forming