CR MeP

ECOLE DES MINES D ’ALBI

RESEARCH CENTRE ON TOOLS, MATERIALS AND

PROCESSES

CROMeP

CROMeP_2000_eng _LP_I 6-00

CR MeP

7 schools Financed and run directly

by Ministery of Industry

FRENCH ECOLE DES MINES NETWORK

PARIS

Toulouse •

• Bordeaux

• Montpellier

Douai •

Nantes

• Alès

Nancy

• Saint Etienne

SPAIN

BELGIUM

GERMANY

SWITZERLAND

ITALY650

km

Albi

• Lyon

• Bruxelles

Barcelone •

250

km

• Frankfort

• Geneva

Milano •

CR MeP Centre de Recherche sur les Outillages, les Matériaux et les

Procédés

Research Center on Tools, Materials and Processes

Founded in 1993

Industrial oriented research global approach for tooling and processes problems

Research on tool materials used in

forging, casting, hot rolling, sheet metal forming, superplastic forming, injection molding, glass industry, etc

CR MeP WHY THIS THEME ?

Significant ecomical impact in material industry direct : raw materials, machining, treatment indirect : cost saving, product quality, productivity

R &D in a industrial company Partially activity Tool manufacturing is often subcontracted Diversification of professions Multidisciplinary problems

CR MeP TEAM

In 12/17/99 : 45 persons

18 scientists & engineers

5 technicians

2 secretaries

19 Ph.D. students

2 Post-Doc

CR MeP PLURIDISCIPLINARY APPROACH

Microstructure &Damage

Characterization

Thermal & Mechanical analysis of tools

- undersdanding - optimisation

- prevision

Material Processes- metals - polymers- glasses - ceramics

- composites - ...

Material TestingTool coating testing

Physical characterizationof materials

Non destructive testing

Surface treatment,coating & lubrification

Process & flow simulation

Thermo-mechanical analysisof molds, dies and tools (FE).

Mold, dies & tools testingon pilot plants

Computer vision appliedto process control

Thermal monitoring of industrialequipments; Infra Red

Thermography

CR MeP 4 SCIENTIFIC RESEARCH AXIS

Measurement of tool sollicitations Heat flux, temperatures and displacements

Contact less measurement technics (CCD cameras, infra-red)

Behaviour and reliability of tool materials Material behaviour and modeling

Isothermal and non-isothermal

Surfaces Performance reliability of tools surfaces

Thermomechanical fatigue life, wear and damage

Modeling and design of tools Coupled or un-coupled mechanical, thermal and chemical modelling

CR MeP TEST FACILITIES

• Mechanical• isothermal fatigue (1200°C)

• non-isothermal fatigue (induction)

• mechanical & optical extensometry

• High temp. flexural on ceramics

• micro- hardness (RT and HT)

• high temperature Charpy

• Thermal expansion

• Microstructural analysis• metallographic examination

• image analysis

• S.E.M.with EDXS& EBSP (local

crystaline orientation)

• X ray surface residual stress

measurement

• 3D nano roughness (with & without contact)

• Portable monitoring equipments• infra red cameras (3-5µm & 8-12µm)

• thermocouple acquisition system

• image acquisition (C.C.D.)

• Pilot plants• thermoplastic injection

• Aluminium casting equipment

• Wear in sheet metal forming

• Thermal treatment

• Software• process simulation

• forging,rolling,forming : FORGE 2

• stamping : PAM-STAMP

• casting : Thercast

• Plastic injection : IDEAS

• thermal & surface treatment : SYSTUS

• thermomechanical analysis : ABAQUS, SYSTUS

• CAD : IDEAS, AUTOCAD

CR MeP RESEARCH CONTRACT ORIGINS

Industrial contracts

•Regional

•National

•European Community

CR MeP MANPOWER RESOURCES AND RESULTS

Research turnover (Million of FF)

1,1

3,3

1,9 2

3,7

00,5

11,5

22,5

33,5

4

1995 1996 1997 1998 1999

CR MeP RESEARCH APPROACH

Two basic orientations

• A-Laboratory scale : Materials characterization and

assessment

• B-Pilot scale : Reproduce and simulate phenomena

to reach scientific unterstanding and develop the behaviour and

life prediction models

CR MeP MATERIALS CHARACTERIZATION

1-Identification of the initial state of material and their

development Mechanical properties & behaviour laws measurements

Cracks, thermal & mechanical damage identification

Assessment of the process induced sollicitations

Development of interactions between processes and tools

2-Monitoring & identification of industrial equipment

operating parameters with mobile equipments Stereovision rigs

CR MeP

Carbide micro-crack after monotonic load at 500°C

Thermomecanical stress during fatigue test at

500°C and 900°C

Choi, Baleix, Bernhart, Lours Superplatic forming

Mechanical properties & behaviour laws measurements

CR MePCracks, thermal & mechanical

damage identification

Uniaxial and biaxial crack during thermal fatigue

Temperature effect on the thermomechanical life

Jean, Oudin, Miquel, Rezai-Aria Forging

CR MeP Assessment of the process induced sollicitations

Numerical simulation of forging operation

with FORGE2Fatigue life calculated

Oudin, Penazzi, Rezai-Aria

Critical area prediction and

time life

Forging

CR MeP Development of interconnections beetween process & tool

Cracks in casting mold

Mold : cast-iron

Baroucaire, Michrafy, Dour

Thermo-elastic stress during aluminum casting

mold : 240°C - Al : 750°C

Casting

CR MeP Monitoring & identification parameters with stereovision rigs

3D shape measurement with stereocorrelation method 2D crack propagation an dfrfacture

thougnhess measurement during 3 points bending test

Garcia, Orteu, Rezai-Aria

CR MeP

Dilation evolution of refractory concrete

reinforced by metallic fibers

Microstructure and behavior of reinforced concretes

Cailleux, Cutard, Bernhart

Prototype insert moulds

Superplastic forming

CR MeP

Temperature contours of preform and lighters during

heating

Infrared heating of thermoplastic preform

Monteix, Le Maoult, Schmidt

Modeling of preform heating

Thermoplastic heating

CR MeP REPRODUCE & SIMULATE PHENOMENA

With classical or special designed test equipments Thermal and mechanical test equipments Tribology and wear test facilities

With instrumented industrial or pilot equipments Sheet metal forming tools wear resistance Plastic injection facilities Heat treatment and quenching facility

CR MeP Thermal and mechanical test equipments

Thermomecanical fatigue machine Thermal fatigue rig

Material behaviour laboratory

CR MeP Tribology and wear test facilities

HT Tribometer equipement Friction coefficient variation with sliding length for 35NCD16 steel

Tribology laboratory

Without oxydationPre-oxydation 400°CPre-oxydation 750°C

Boher, Vergne

Time (s)

CR MeP Sheet metal forming tools wear resistance

Technical Hall

Sheet metal forming pilot Tools geometries

Strain gages and thermocouples instrumented tools

3-axials force cell5 KN - 150 mm/s - continuous or 10 cycles/min - coil : 200 kg

Boher, Lamesle, Penazzi

CR MeP

Technical Hall

Injection facilities

Injection moulding machine with modular molds

Wesselman, Saint-Martin, Devos

CR MeP Heat treatment & quench facility

Thermal and surface traitement laboratory

Heat treatment

vacuum furnace quenching

End 135s 55s 50s 225s 110s 25 s

Shape variations monitoring for Austenitic Stainless Steel X2CrNi18-9 during cooling

Claudinon Lamesle, Orteu

CR MeP

Aim To promote exchanges between research groups involved in

Forming Tools (from academic institutions and technical centers) To prepare common response to international calls for proposal

(like EEC programs) To reinforce lobbying inside national and international committees

to promote research and education of engineering students on forming tools

To organize conferences, workshops and short courses on the forming tools domain

To develop data base and information collection on forming and molding tools

forging, superplastic forming sheet metal forming casting, injection moulding,

International Network on Forming Tools Research and Development

CR MeP

Call for partnership to join the International Network on Forming Tools Research and Development

Please contact :

Prof. C .LEVAILLANT

Head of CROMeP Research Centre

Ecole des Mines d ’Albi

F-81013 ALBI cedex 09 - France

Phone : +33 563 49 30 79 - Fax : +33 563 49 32 42

email : levaillant@enstimac.fr

http://www.enstimac.fr/

International Network on Forming Tools Research and Development

CR MeP

Cases of sheet metal forming tools 75 references papers from 1997 to 1999

Main country : France, Germany, USA, etc

Main actors : Aalborg Univ., Hanovre Univ., MIT, Ohio State Univ., TNO, etc

Main topics : Friction, design, material, tool

technology, etc

International Network on Forming Tools Research and Development

BH2%

design15%

friction24%

material13%

tool technol.

11%

computer simulat.

10%

coating.8%

economic5%w ear

8%

control2%

manufact.2%

CR MeP

Post-doc students mechanical and materials sciences work proposed :

sheet metal forming tools (material, coating, wear)

tribology at high temperature

Visiting professors mechanical and material sciences at least 6 months

EXCHANGE OFFERS