Optimization of High-Volume Warm Forming for Lightweight Sheet

Harrison, Nia R.; Ilinich, Andrey; Friedman, Peter A.; Singh, Jaspreet; Verma, Ravi

doi:10.4271/2013-01-1170

Cited by 13 publications

(17 citation statements)

References 9 publications

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“…EVolution (FP7/2007-2013 stands for "The Electric Vehicle revOLUTION enabled by advanced materials highly hybridised into lightweight components for easy integration and dismantling providing a reduced life cycle cost logic".…”

Section: Evolution Project Goalsmentioning

confidence: 99%

“…The underbody was conceived through an integrated approach, leveraging new process technologies (D'Annibale, 2014;Harrison et al, 2013) to merge in a unique new component as much parts as possible, optimising each element for its function (Figure 15). This methodology allowed the maximum potential for weight saving with respect to Nido underbody: proposed technologies enabled complex geometries with reduced thickness and a consistent part count reduction.…”

Section: Underbody Demonstratormentioning

confidence: 99%

See 1 more Smart Citation

Evolution FP7 funded project: body structure design strategies using new composite and aluminium materials and enabled technologies

Mangino

Alcalde

Maestro

et al. 2017

IJAUTOC

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Based on Pininfarina Nido EV concept, EVolution aims to reduce the vehicle weight through new materials and process technologies, focused on five demonstrators: underbody, front crossbeam, mechanical subframe, shotgun system and door. This paper refers to body structure design strategies using new composite, Al materials and enabled technologies, focusing in particular on demonstrators design and manufacturing. The new front crossbeam geometry of the front shell is adapted starting from the Nanotough design, while the rear shell is specific for EVolution. The subframe demonstrator is redesigned to fulfil mechanical requirements of the part and manufacturing feasibility either. The EVolution door concept consists of two semistructural Evolution FP7 funded project: body structure design strategies 253 composite skins including a structural Al frame. The underbody is conceived through an integrated approach, optimising each element for its function. The shotgun component is designed to link parts obtained with different manufacturing technologies and several aluminium alloys in one single component: the structural node demonstrator.

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Section: Evolution Project Goalsmentioning

confidence: 99%

Section: Underbody Demonstratormentioning

confidence: 99%

Evolution FP7 funded project: body structure design strategies using new composite and aluminium materials and enabled technologies

Mangino

Alcalde

Maestro

et al. 2017

IJAUTOC

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show abstract

“…Its temperature was measured immediately before the forming process and was about 50°C cooler than the temperature at the furnace exit, highlighting the heat losses to the environment during the movement of the blank to the press. In order to optimize the warm forming process in terms of production robustness and costs, Harrison et al [16] present a non-isothermal method. Only the blank (5182-O aluminium alloy) was heated inside a furnace using an exposure time of 180 s to reach the warm forming temperature.…”

Section: Furnacesmentioning

confidence: 99%

“…However, this heating stage is typically overlooked in the numerical modelling of the process, as well as the cooling of the blank that occurs during its transport to the press, in case of external heating [16]. In fact, the temperature of the blank is commonly assumed uniform at the beginning of the forming stage in the finite element analysis.…”

Section: Introductionmentioning

confidence: 99%

Numerical analysis of different heating systems for warm sheet metal forming

Martins

Alves

Neto

et al. 2015

Int J Adv Manuf Technol

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The main goal of this study is to present an analysis of different heating methods frequently used in laboratory scale and in the industrial practice to heat blanks at warm temperatures. In this context, the blank can be heated inside the forming tools (internal method) or using a heating system (external method). In order to perform this analysis, a finite element model is firstly validated with the simulation of the direct resistance system used in a Gleeble testing machine. The predicted temperature was compared with the temperature distribution recorded experimentally and a good agreement was found. Afterwards, a finite element model is used to predict the temperature distribution in the blank during the heating process, when using different heating methods. The analysis also includes the evaluation of a cooling phase associated to the transport phase for the external heating methods. The results of this analysis show that neglecting the heating phase and a transport phase could lead to inaccuracies in the simulation of the forming phase.

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“…The objective of the work done by Harrison et al [10] was to develop a warm forming process that both retains the benefits of traditional warm forming while allowing for the use of lower-cost tooling. The results revealed that nonisothermal warm forming could enable sufficient formability to stamp a one-piece door inner panel from commodity aluminium alloys.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigations of Induction Heating in Warm Forming of Stainless Steel Sheets

Smusz

Trzepieciński

Malinowski³

et al. 2018

Teh. vjesn.

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The main objective of this study is to investigate the effect of heating conditions on the temperature distribution in sheet metal. An AMS5604 stainless steel sheet was heated in an induction heater. Then, the hot workpiece was transported to the stamping tool. The uniform temperature distribution is a key factor influencing the possibility of forming and quality of warm-formed parts. To study the temperature distribution in sheet plate we carried out the measurements using termoelements. Furthermore, thermovisual measurements were performed using a FLIR P 640 thermovisual camera. It was found that to improve the uniformity of the temperature distribution in the workpiece the time of heating should be increased. However, the time of transport of the sheet to the tool should be decreased. During air cooling a decrease of the difference between the maximal and minimal temperature of the sheet is observed.

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Optimization of High-Volume Warm Forming for Lightweight Sheet

Cited by 13 publications

References 9 publications

Evolution FP7 funded project: body structure design strategies using new composite and aluminium materials and enabled technologies

Evolution FP7 funded project: body structure design strategies using new composite and aluminium materials and enabled technologies

Numerical analysis of different heating systems for warm sheet metal forming

Experimental Investigations of Induction Heating in Warm Forming of Stainless Steel Sheets

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