introduction of ewi forming center nov 2012
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November 14, 2012
Introduction of EWI Forming
Center
Ron Brown
Director
EWI Forming Center
Office 614-688-5085
E-mail: [email protected]
Hyunok Kim
Technical Director
EWI Forming Center
Office: 614-688-5239
E-mail: [email protected]
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- 11 Top Cross-Cutting Technologies -
Advanced FormingAnd
Joining Technologies
pivotal in enabling U.S. manufacturing competitiveness
Background
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Presidents Council of Advisors on Science and Technology
JULY 2012
REPORT TO THE PRESIDENT ON CAPTURING DOMESTICCOMPETITIVE ADVANTAGE
IN ADVANCED MANUFACTURING
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EWI & OSU
Meeting the challenge thru collaboration
OSUCenter
For
PrecisionForming
EWI
Forming Center
Background
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EWI & OSU
Meeting the challenge thru collaboration
EWIForming Center
Chairman - Dr. Taylan Altan
Director Ron Brown
Technical Director Dr. Hyunok Kim
Unique in the western hemisphere
Background
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The mission of the center is to develop and advance innovative
forming processes, tooling, and equipment; provide a technology
and knowledge base to industry and government; and cooperate
with the Ohio State Universitys Center for Precision Forming (OSU-
CPF) to conduct fundamental research while training new
engineers for the forming industry.
Mission
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Establish Forming Center at EWI in cooperation with CPF-Center for Precision
Forming of OSU Provide the knowledge base and infrastructure that exists at EWI and CPF (160
ton hydraulic press and tooling moved to EWIs laboratory)
Establish cooperation with EWI and CPF staff and students to conduct projects for
industry and government
Utilize the strengths of both EWI and CPF in technology as well as business.
Thus, while establishing and expanding the EWI-CPF continue to maintain CPF
as the university link and fundamental research support.
Continue to maintain and expand the close cooperation EWI and CPF have with
companies interested in joining and forming technologies.
Strategy
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EWI-Joining R&D
EWI-Members
AutomotiveAerospace
Energy
NSF/ othergovernment
EWI-
FormingCenter
Activities-R&D in Sheet Forming Material characterizations/ formability Friction/lubrication Process simulation/quality/springback Fabrication
CPF-OSU
Industry, 15 companies(OEM/s, 1ST Tier, software,
tooling)
Close cooperation
Structure of EWI Forming Center
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Effort
Basic R&D
CPF-OSU
EWI-Forming Center
Proof of conceptLubrication application
Prototyping(pre-production)
From R&D to Production
EWI-Forming Center and CPF-OSU Activities in R&D
Activities of EWI Forming Center
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Create a Forming Center website Establish a group of friends of the Center Hold a semi-annual workshop (Next in March 2013) Email quarterly R&D updates Publish industry-related non-proprietary results
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The centers inaugural event, a joint workshop with OSU-CPF on Advance Sheet
Metal Forming Technology at EWI headquarters on November 14, 2012.
Next Step
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Forming Equipment at EWI
Type Minster Tranemo DPA-160-10Slide Force 160 metric tons (176.4 tons)
Cushion Force 100 metric tons (110.3 tons)
Eject Force 15 metric tons (16.5 tons)
Slide Speed 90 mm/s maximum (3.54-inch/s)
Slide Stroke 500 mm (19.68 inch)
Platen Size 1,000 x 1,000 mm(39.37 x 39.37 inch)
Test tooling 7 different testing die sets availablewith the press
160-ton Minster Tranemo Press(Installed at EWI in Sept. 2012)
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Formability tests:
Tensile (up to 1000F) test
Biaxial bulge test Billet upsetting and extrusion tests
Friction, Lubrication and Tool wear tests Strip galling test
Deep drawing test Limiting Dome Height (LDH) test Ironing test with heated dies Double cup extrusion (DCE) test
Stamping tests Bending and Flanging tests Rectangular deep drawing test Springback tests
Biaxial BulgeTested Sample
(12-in x 12-in)
Forming Test Capabilities
Deep Drawn Sample(6-in bottom dia. x
3.5-in. depth)
DCE Tested Sample(1-in. dia. x 2.5-inch
height)
Rectangular Drawn Sample(20-in. x 18-In. x 2-in. depth)
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Process Simulations
Sheet Metal Forming
- Springback
- Failures (necking and wrinkling)
- Tool stress and wear
- Tool design and process optimization Bulk Metal Forming (Forging)
- Die stress and temperature distribution
- Optimized die shape
FE Modeling Tools- ABAQUS
- DEFORM
- LS-DYNA
S-rail stamping simulation
Simulation Capabilities
FEM of automotive part
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Questions?
Ron BrownDirector
EWI Forming Center
Office 614-688-5085
E-mail: [email protected]
Hyunok KimTechnical Director
EWI Forming Center
Office: 614-688-5239
E-mail: [email protected]
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