Intensive Training in Press Hardening. Module B Virtual Process Design for Hot Stamping of Ultra-High-Strength Steel

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1 Intensive Training in Press Hardening Module B Virtual Process Design for Hot Stamping of Ultra-High-Strength Steel

2 Presented by: Scientific management: GRUNDIG AKADEMIE, Academy of Economics and Technology Prof. Dr. Kurt Steinhoff, Chair of Metal Forming Technology, University of Kassel The GRUNDIG AKADEMIE was founded by Max Grundig more than 30 years ago. He was one of Germany s most successful entrepreneurs and set the academy up as a non-profit organization. Since then GRUNDIG AKADEMIE has been a reliable training partner for many companies, organizations and individuals. The academy offers a broad range of professional education, from technical vocational schools to open enrolment courses in management, IT and engineering and long term vocational training with certified diplomas. Pictures: AutoForm, private 2

3 Introduction During the last decade, hot sheet metal forming technology, better known as press hardening or hot stamping, has certainly become all pervasive in automotive body-in-white design. Driven by a strong demand for further improvement of energy efficiency and passenger safety, today, hot stamping is undoubtedly a sustainable global technology. The expected surge in growth of this technology in part production, material supply, production equipment etc., has recently encouraged quite a few players to enter this highly specialized technological scene. Competition has risen inexorably and the ability to act globally has certainly become an existential challenge. However, it has become clearly understood during these years that press hardening is an inevitably knowledge-driven technology. Without a proper understanding of the governing thermo-mechanical mechanisms it is perhaps possible to move along to the low-end of technology but impossible to reach the high-end. Because of this, there are some very promising opportunities for SME companies in reaching and/or maintaining their position at the high-end of hot stamping technology and to share/benefit from the high level of added value. The acquisition of substantial knowledge, therefore, constitutes the main key to be successful in the aforementioned sense. This series of intensive trainings, each focusing on a particular aspect of technology, offers comprehensive access to valuable knowledge on hot sheet metal forming. Prof. Dr. Kurt Steinhoff Prof. Dr.-Ing. habil. Kurt Steinhoff 3

4 Overview Benefits Courses Module B The Intensive Press Hardening Seminar is aimed at combining practical experience, fundamentals and innovative technologies on the shop floor level. Technicians and practicians will achieve a comprehensive knowledge in the rapidly growing technology field of press hardening, enabling them to cope with the recent developments in companies applying state-of-the-art hot sheet metal forming processes. The attendee will receive innovative and scientifically proven knowledge which will give them the opportunity to fill a leading role in implementing and utilizing this technology on a practical level. A detailed view about the technical surroundings such as the behaviour of special steels concerning heat treatments and hot forming as well as the appropriate manufacturing equipment and testing methodology will be given in theory and practice. The overall performance and the variety of methods of the seminar are designed most helpful for efficient studying. You will have the opportunity to experiment with various parameters and experience Hot Sheet Metal Forming in the field and acquire a deep insight into efficient skills in technology. Seminars B1 Heat Treatment and Hot Forming of Steel B2 Press Hardening Processes B3 Finite Element Model and Simulation Setup B4 Process Simulation and Result Evaluation B5 Advanced Simulation Techniques Practical Laboratory Internship B2 Laboratory Internship Revision Course Exam Closing Meeting Course Schedule Time Day 1 Day 2 Day 3 Day 4 08:30 10:15 B2 Seminar Exam Arrival B4 Workshop 10:15 12:00 B2 Laboratory Internship Closing Meeting 12:45 14:30 Introduction B4 Workshop 14:30 16:15 B3 Seminar B5 Seminar B1 Seminar 16:15 17:45 Revision Course Departure 4

5 Facts and Figures Target Participants Engineers, technicians and foremen in the fields of production, quality assurance, assembly and process planning Venue University of Kassel, Chair of Metal Forming Technology Certificate of Performance Contact Your personal contact for this course is: Technical Consultant Christian Kovacs Phone: +49 (0) Fax: +49 (0) Direct Marketing and Sales GRUNDIG AKADEMIE GRUPPE TOP Business AG Klingenhofstrasse Nuremberg Germany IIA two-hour written examination following a revision course IIA certificate of participation issued by the GRUNDIG AKADEMIE Course Schedule IISee schedule timetable IIDinner on the last evening Terms of Conditions IISeminar fee (per person): available on request. IIGroup size is limited to 8 participants. IIThe seminar price includes course participation, laboratory use, seminar charge, dinner on the last evening of the course, and all training materials. IIWe will gladly provide you with hotel recommendations for accommodation. IIAll participants receive a certificate from the GRUNDIG AKADEMIE. 5

6 Module B Virtual Process Design for Hot Stamping of Ultra-high Strength Steel B1 Heat treatment and hot forming of steel B3 Finite Element Model and Simulation Setup A comprehensive understanding of the interaction between heat, phase transformation, plastic deformation, microstructure and mechanical properties will be provided. Using their acquired knowledge and skills, participants will be able to follow thermal and mechanical process routes and resulting properties for selected heat treatable steels including determining and verifying the thermal and mechanical process parameters hereby provided by means of appropriate material testing methods. In a seminar, the basic principles of heat treatment and hot forming of steel are presented. These particularly concern the fundamental interactions of heat, phase transformation, plastic deformation and resulting microstructures and mechanical properties including temperature dependent flow stress and formability. IIDuration: 4 hours seminar An overview of important input parameters for a thermomechanical finite element simulation will be presented. The objective of this lecture is to provide a comprehensive understanding of a finite element model and how physical effects are taken into account during process simulation Press hardening is much more complex than cold stamping, because of the various interactions between mechanical, thermal and metallurgical effects. During this lecture it will be explained step by step how to extend a simulation model from a conventional stamping process to the requirements for an accurate press hardening process simulation. The generation of the simulation model has three major topics material properties (temperature and strain rate dependent), heat flux (within the blank, between blank and tools/ambient), phase transformation and final product properties. Easy and comprehensible examples are used to explain how experimental results and physical parameter incorporate into the finite element model. Simulation based design studies will show the sensitivity of the model parameters IIDuration: 4 hours seminar B2 Press hardening processes An overview over different variants of hot stamping processes will be provided from a material-oriented technological point of view as well as from a process-oriented point of view. Participants will acquire the ability to reliably handle and apply state-of-the-art material systems under industrially relevant press hardening conditions. A major challenge in press hardening is constituted by the requirement to establish a reproducible, reliable and robust process despite of the complex combination between heat treatment and forming in an integrated process sequence. Different variants of press hardening processes, both from a process-oriented technological viewpoint as well as from a material-oriented technological viewpoint, will be explained in detail in seminar presentations. The individual properties of different material systems will be taken into account. Process strategies of time dependent and locally variable temperature control, with the aim of creating graded or tailored component properties, will be covered. Additionally tribological aspects of specific contact conditions are considered. This knowledge will then be reinforced by practical work experience in the laboratory on the basis of press hardening trials. IIDuration: 2 hours seminar / 2 hours practical laboratory internship Simulation of the quenching process step 6

7 Module B Virtual Process Design for Hot Stamping of Ultra-high Strength Steel B4 Process Simulation and Result Evaluation B5 Advanced Simulation Techniques Simulation of press hardening processes offers the chance to shorten development cycle times. This session provides an overview of engineering tasks that can be solved with finite element analysis in an industrial development environment. Press hardening is an innovative technology that develops fast. of this seminar is to provide insights of current trends in advanced simulation techniques and the simulation of the various press hardening process strategies. Different options for a simulation setup for industrial purposes will be introduced and discussed with respect to their strengths and limitations. In an early phase of development the main task is to quickly evaluate concepts and to ensure a feasibly part. Later in the engineering workflow, before the tools are released for milling, the focus of the simulation setup is on accuracy to finally validate the press hardening process. With respect to efficiency it is reasonable to adapt the simulation setup according to this two contrary requirements from fast to accurate. During this workshop session typical engineering tasks will be discussed. In shop exercises simulation results are used to define the blank outline and blank position, optimize temperature control, avoid wrinkles and cracks, generate input for crash analysis (result mapping). IIDuration: 6 hours seminar Stamping simulation and press hardening technology continuously develop innovations. During this seminar advanced simulation techniques will be introduced. Based on an example for direct press hardening of a B-pillar the simulation input definition will be modified to investigate various press hardening process strategies direct versus indirect press hardening, tailor welded and tailor rolled blanks, tailored tempering. Furthermore simulation setups that address classical optimization issues are presented minimum blank outline to save material systematic process improvement based on automatic parameter variation optimization of process window to ensure a robust production IIDuration: 1,5 hours seminar Feasibility assessment at an early stage of development Simulation of a tailored tempering process 7

8 Your Trainers Prof. Dr.-Ing. habil. Kurt Steinhoff Professional experience in metal forming technology both in industry and in science for 20 years. Has established the internationally leading research site for the development and production of hot formed ultra-highstrength body-in-white components. IIMSc, Mechanical Engineering, Gerhard- Mercator-University of Duisburg, Germany IIPhD & Habilitation and venia legendi, RWTH Aachen, Germany IIFull Professor of Metal Forming Technology, University of Kassel, Germany IIAssociate Professor of Production Technology, Delft University of Technology, The Netherlands IIResearch Assistant, Department of Metal Forming Technology, Max-Planck-Institute for Iron Research, Düsseldorf, Germany IIManagement positions in Cold Strip Production and Research & Development in Steel & Automotive/Aerospace/Defence Industry Dr.-Ing. Ursula Weidig Specialist for thermo-mechanical processing technologies IIMSc Metallurgy and Material Science, RWTH Aachen IIResearch Assistant, Chair of Metal Forming Technology, Max-Planck-Institute for Iron Research, Düsseldorf, Germany IIPhD Thesis, Thermo-mechanical processing with Dieless Drawing, RWTH Aachen, Germany IIResearch & Development/QS, RUAG Components, Altdorf, Switzerland IICEO of the Collaborative Research Center SFB/TR 30 Processintegrated manufacturing of functionally graded structures on the basis of thermo-mechanically coupled phenomena IIAssistant Professor, Metal Forming Technology, University of Kassel, Germany Dipl.-Ing. Thomas Schönbach Technical Product Manager of a finite element solver specialized for sheet metal forming processes. 20 years experience in sheet metal forming simulation IIMSc, Mechanical Engineering, Technical University Dresden, Germany IIForming simulation/cae specialist, Audi AG IITechnical Product Manager, AutoForm Engineering Deutschland GmbH Dr.-Ing. Michael Kerausch Product Manager for stamping simulation software that is used in the engineering workflow of sheet metal forming processes in automotive industry IIMSc, Mechanical Engineering, Friedrich- Alexander-University Erlangen-Nuremberg, Germany IIPhD, Chair of Manufacturing Technologies, Erlangen, Germany IIResearch Engineer, Chair of Manufacturing Technologies IITechnical Key Account Engineer, AutoForm Engineering Deutschland GmbH IIProduct Manager, AutoForm Engineering Deutschland GmbH Dipl.-Ing. Agim Ademaj Program Coordinator for Hot Stamping Technology IIMSc, Mechanical Engineering, University of Kassel, Germany IIProgram Coordinator, Metal Forming Technology, University of Kassel, Germany 8

9 GRUNDIG AKADEMIE Akademie für Wirtschaft und Technik Gemeinnützige Stiftung e.v. Beuthener Straße Nürnberg Contact Mr. Christian Kovacs Phone Mail Phone Fax Mail