www.mn-coil.de

Benefit from the advantages of high-speed

cutting by MN Coil Servicecenter, proven

by Forschungsgesellschaft Umformtechnik

Stuttgart:

• 20% higher rest formability at the edge

of the blank compared to laser cutting

• up to 5% material savings

• higher process reliability

• shorter simulation time

20%HIGHER REST

FORMABILITY

Edge cracking study, FGU Stuttgart

DIABOLO test - Edge Conditions

Coil Servicecenter GmbH

High-precision 2D aluminum blanks

Coil Servicecenter GmbH

Best forming results through HSC cutting

Sheet thickness 0.5 - 5.0 mm

Cut to width Customized blanksCut to length

Length 150 - 8,000 mm

Width uo to 2,050 mm

Length 500 - 8,000 mm

Step 1

Width > 100 mm x 6

Length up to 4,000 mm

Width up to 2,000 mm

Step 2 Step 3

MN Coil Servicecenter GmbH is one of the most modern

coil centres in Europe and the specialist for high-preci-

sion 2D aluminum blanks. MN Coil Servicecenter is

your partner for:

• Series where the procurement of cutting tools would

be uneconomical

• Series ramp-ups where the use of cutting tools has

not yet been decided

• Reworking for special vehicles and models

• Spare part requirements

• Bridging of delivery bottlenecks

• Exclusive and small series

MN Coil Servicecenter GmbH

is certified to

• IATF 16949 and

• DIN EN ISO 9001:2015

MN Coil Servicecenter GmbH

Industrieweg 34 I D-23730 Neustadt

Tel.: +49 (0)4561 5179-0

E-mail: info@mn-coil.de

TÜV NORD CERTGmbH

IAT

F 16949/ISO 9

001

www.mn-coil.de

Laser CO2, output: 6kW, cutting gas: nitrogen

Water jetSystem pressure: 4000 bar

HSC milling process at MN CoilCutter Ø: 6 mm

Stamping, new tool Cutting gap: 0.06 mm, cutting edge roundness:

none

Stamping, used tool Cutting gap: 0.06 mm, cutting edge roundness:

300 µm

DIABOLO test - Setup

Optical

measuring

system

PunchPunch

Specimen Specimen Blank holder

DieDie

Total number of tests: 200

100 mm

1. The HSC method demonstrated the best results for

all alloys investigated in the DIABOLO test.

2. The cut edges resulting from the HSC method have

approximately 20% higher rest formability on average

compared to the laser cut samples.

0,000

0,100

0,200

0,300

0,400

0,500

0,600

0,700

0,800

Laser Water jet HSC Stampingnew tool

Stampingused tool

max

. deg

ree

of p

rinc

ipal

def

orm

atio

n

Three different component geometries were tested in

an AutoForm R7 simulation: Door inner part, wheel-

house and B-pillar.

The material data in the simulation software were

supplemented by the experimentally determined

measured values. This determined the edge crack

criterion.

Components are usually designed with a criterion of

0.8, i.e. 20% process safety. Cracks would occur in

the components as of a value of ≥1.

1. HSC-milled edges result in higher formability

and higher process safety, which means that

neither method optimisation nor component modi-

fications are necessary, as would be the case with

stamping.

Door inner part - relief hole

Edge crack used tool: 0.932

Edge crack HSC: 0.546

2. Components formed from HSC-cutted sheets can

be produced with harder beads and higher blank

holding forces. Stamped components in contrast

need softer beads and larger feeder which increa-

ses material consumption.

B-pillar - beads

Edge crack used tool: 1.065

Edge crack HSC: 0.624

3. HSC-milled edges lead to material savings of up

to 5%, as shown in the wheelhouse relief hole

example, as more material can flow out from the

inside during forming.

Wheelhouse - relief hole

Edge crack used tool: 1.374

Edge crack HSC: 0.755

DIABOLO test & Simulative investigation Simulative investigation

Test results

Simulative investigation

Test results

5182 1,15 mm

6016 1,70 mm

5182 1,15 mm

www.mn-coil.de

Coil Servicecenter GmbH

2D blanks made of aluminum - a growing market

The material aluminum has become one of the most

important lightweight materials in the automotive

sector over recent years, which in turn means the

demand for customized blanks is rising continuously.

The quality requirements for these blanks are also

increasing.

The Forschungsgesellschaft Umformtechnik Stuttgart

(FGU) carried out an edge cracking study in 2019 in

order to determine the quality of customized blanks

produced by MN Coil Servicecenter and their HSC

method.

The production processes involved in edge cutting and

the cut edge properties/characteristics themselves

influence the rest formability of the sheet edge.

The formability of sheet materials is reduced due to the

strain hardening caused by stamping. This increases

the crack sensitivity of edges, particularly in the case

of high and ultra-high lightweight sheet materials. The

MN Coil HSC process was compared with conventional

production processes in practical tests (DIABOLO test)

and simulative evaluations (AutoForm R7). The test

results speak for themselves.

In the DIABOLO test, the samples (4 alloys, 5 cutting

methods) were formed until an edge crack occurred

and the maximum sustainable principal deformation

before start of failure was determined.

DIABOLO test

Alloy and material thickness:

5182 1,15 mm

6016 1,70 mm

5182 1,75 mm

AL6 1,10 mm