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Great Designs in Steel is Sponsored by:AK Steel Corporation, ArcelorMittal Dofasco, ArcelorMittal USA,
Nucor Corporation, Severstal North America and United States Steel Corporation
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Tailor Welded Coils:Tailor Welded Coils:Applications, Results & Body Structure ImpactApplications, Results & Body Structure Impact
Mark EisenmengerTWB Company LLC
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Agenda
Review Tailor Welded Blank Applications
Evolution of Tailor Welded Blanks to Tailor Welded Coils
Application and Results of Tailor Welded Coils
BIW Impact with Tailor Welded Coils
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Tailored Product Benefits
GeneralProduct Benefits
Part Reduction/IntegrationMass/Weight SavingsImprove Functionality
Manufacturing BenefitsReduce Manufacturing Complexity Improve Dimensional Control
Cost BenefitLower Tooling & LaborReduce Number of OperationsLess Material Handling & Enhanced Logistics
Material Cost Reduction (MCR)Improved Material Utilization
NestingScrap Reduction
• Optimize Steel Properties Throughout the Part
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Tailor Welded Blank Applications
There are 18 common tailor welded blank automotive applications
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Welding Process
Butt Weld (no filler)Continuous Flow Welding processGauge Possibilities: 0.4mm to 3.5mmWeld Lengths – up to 4 metersMaterial Combinations Include:
Stainless CR, HR, Zn Coated, DP, TRIP,CP and boron gradesEach weld is computer monitored and serialized
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Quality Monitoring
TWB utilizes:Online
Weld profile monitoringMagnetic Flux Leakage Detection (MFL)
SamplingCross sectional analysisVisual inspection
Result: Six Sigma Quality Levels (External PPM 3 or less!)
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Tailor welded coils provide specific product benefits:
Exact grade, coating and gage of steel where it is needed.
Cost reduction with part consolidation.
Lighter weight and improved part performance.
Tailored products in coil fed products such as progressive die and roll-forming.
A Breakthrough ProcessTailor Welded Coils:
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Continuous process that consists of:
Un-coiling / LevelingWelding Re-coiling
Process OverviewTailor Welded Coils:
Monitoring &Reporting
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Utilize the same quality criteria for tailor welded blanks and tailor welded coilsWeld defects are identified and mapped for each coilThe result is improved material utilization with minimal material loss
Coil Map
Quality MonitoringTailor Welded Coils:
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Weld defects are identified and mapped for each coil with customer specified methods
Typical methods include: Punched hole, Ink jet, Metered report
Punch
Punched Hole
Weld Defect
Ink Jet
Coil Map ExampleTailor Welded Coils:
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Production MachineTailor Welded Coils:
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Progressive Die TWC Applications
There are more than 35 potential tailor welded coil automotive applications
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Potential Applications for TWC
Seat tracks, supports and seat frames Door intrusion beamsDoor belt reinforcementRoof headers and railsRoof cross railsPlenum floorBumper beamsSillsFloor pan strainerChassis componentsRail back platesSun roof reinforcements
Door beam
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Progressive Die Operation
Coil fed operations with tailored steel enable:
lower die & assembly investmentmaterial savingspart weight savingsimproved part performanceimproved dimensional control
Finished PartTailored Coil
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Progressive Stamping TWC Parts
Saves 2.0 pounds / vehicleSaves $1.50 / vehicle2 parts / vehicleIn production (Germany)
Longitudinal Chassis Beam
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1.35 mm
Roof Cross Member
Progressive Stamping TWC Parts
1.0 mm1.35 mm
Integrates 3 stampings into 1
Improved roof crush and side impact resultsSaves .8 lbs / vehicleSaves $1.60 / vehicleIn production (Germany)
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Part developed by .dwg Design Services
Roof Bow
Progressive Stamping TWC Parts
1.8 mm1.0 mm
Integrates 3 stampings into 1
Improved roof crush and side impact resultsSaves 2.0 lbs / vehicleSaves $2.25 / vehicleProposed (USA)
1.8 mm
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Improves part stiffnessConsolidates 2 stampings into 1Eliminates assemblyStainless steel 439 Saves .25 lbs / partSaves $.95 / vehicleProposed (USA)
Part developed by .dwg Design Services
Heat Shield Assembly
Progressive Stamping TWC Parts
2.3 mm 0.7 mm
0.7 mm
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Saves 2.0 lbs / vehicle (4 parts / vehicle)Costs $.60 / vehicleProposed (USA)
Part developed by .dwg Design Services
Seat Side Member
Progressive Stamping TWC Parts
2.1 mm
1.0 mm
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Integrates 2 stampings into 1Improves interface stiffness Saves .3 lbs / applianceSaves $.45 / applianceProposed (USA)
Part developed by .dwg Design Services
Appliance Mounting Bracket
Progressive Stamping TWC Parts
1.7 mm
1.0 mm
1.3 mm
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Austenitic Stainless SteelSaves 1.0 lb / vehicleSaves $1.42 / vehicleIn production (Germany)
Muffler Shell
Progressive Stamping TWC Parts
1.2 mm
1.2 mm
0.7 mm
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Transfer Press Stamping TWC Parts
2000 Ton Transfer Press580 MPa 1.2 mm / 780 MPa 1.1 mm
Reinf. Compt RR S/Rail
Coil Feed Finished Part
Draw TrimPierce
FlangeRe-strikeCut Cam
Pierce
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BaselineBaselineBaseline
Part Consolidation Savings Example
(2) parts are designed and stamped as
progressive die and assembled
Parts are consolidated as a tailor welded
blank and stamped in a transfer press
Parts are consolidated as a tailor welded coil
and stamped in a progressive die
Investment: $575KPiece Cost: $7.20Weight: 3.62kg
Investment: $395KPiece Cost: $6.69Weight: 3.40kg
Improves:Investment: 31%Piece Cost: 7%Weight: 6%
Investment: $345KPiece Cost: $4.97Weight: 3.40kg
Improves:Investment: 40%Piece Cost: 31%Weight: 6%
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Progressive Die Potential TWC Impact
Optimizing 33 parts tailor welded coil applications
Upper Body
Front End
Under Body
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Potential Impact to BIW Structure
Upper Body (10 applications)6.5 kg of weight savingsProvides the best cost / weight savings ratio
Front End (6 applications) 4.4 kg of weight savingsProvides the highest percentage of weight savings
Under Body (17 applications)12.8 kg of weight savingsProvides the highest number of applications
25 kg of potential weight savings with TWC in BIW
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Key Advantages for TWC
Many parts have a calculated 25% stamping cost
savings with the benefit of weight savings
Lower die investment costs
Potential to convert to more efficient press lines:
tandem press to transfer press
transfer press to progressive press lines
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A Cost Effective Materials Approach
Tailored Coils bring tailor welded blank benefits to progressive die, coil fed stamping processes and roll-forming applications
Tailored products achieve cost effective weight savings to your programs
Summary:
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Thank you!
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Great Designs in Steel is Sponsored by:AK Steel Corporation, ArcelorMittal Dofasco, ArcelorMittal USA,
Nucor Corporation, Severstal North America and United States Steel Corporation