FOCUS ON STAMPING
Thanks to AP & T ’ s FEM sheet-metal forming simulation models , production capabilities were enabled in a really short time frame
AP & T ’ s Dr . Christian Koroschetz and Manager . Development Forming Processes & Tooling , Dr . Michael Machhammer , with a hot-formed complex-shaped door ring component . technology . The potential benefits were significant , because hot-forming enabled the manufacturing of complex part geometries with high-strength aluminium . Thanks to the combination of high formability , high strength and low weight , the design of the components could truly be optimised . This allowed the utility package space to be used more efficiently and us to achieve a high level of collision safety and low energy consumption , all to benefit the end customer ,” said Eric Bach , Senior Vice President of Product and Chief Engineer , Lucid .
Simulations and prototype tools
Complex aluminium component which exhibits design elements from a door ring and door inner geometry .
During 2017 , the development work accelerated with the use of computeraided engineering analysis . AP & T ’ s forming experts executed FEM sheet-metal forming simulations , which predict the possible risks of cracks and wrinkling that could occur during the forming process . Lucid ’ s engineers leveraged the feedback from these simulations to iterate on the car-body component design .
That same year , AP & T presented the first full-scale production line for hot forming , high-strength aluminium to demonstrate the potential of the new technology . The innovation received the prestigious Altair Enlighten Award . This recognition confirmed that AP & T was on the right path and gave extra momentum to its collaboration with Lucid Motors .
In 2019 and 2020 , tests were conducted to validate the robustness of the process and develop test data . While the design of the component is vital to fulfil the carbody crash requirements , the strength , elongation , material and crash folding pattern also play a critical role . Lucid ’ s material engineers and carbody designers collaborated with AP & T ’ s sheet-metal process engineers and identified the ideal materials to meet the required component performance .
Numerous trials of different high-strength aluminium alloys from various suppliers were conducted on AP & T ’ s test line in Ulricehamn , Sweden . The team implemented parameters recommended by these material suppliers into the production process . It was during this project phase that the best material , stamping process and heat-treatment parameters were defined .
The process robustness was validated through an intensive experimental study that included material testing at the suppliers ’ test laboratories and significant component testing by Lucid`s material engineers . Material and
The AP & T demonstrator part exhibits a high degree of complexity , which is required for net-shaped door components such as door rings and door inner shapes .
Hot forming of highstrength aluminium
With AP & T ’ s production technology for hot forming of aluminium , body components which traditionally consist of several joined parts can be formed in a single step . This technology enables net shape forming and thus reduced production time and costs for car manufacturers . To demonstrate the possibilities , AP & T conducted a development project in 2020 to design and manufacture a new tool for complex hot forming .
The outcome of the project was a concrete example of what AP & T can offer the automotive industry in terms of efficiently building lighter and safer cars to reduce CO₂ emissions and the impact of additional system costs for electrification .
Due to the strong formability of the material , components that are currently manufactured by joining several different parts , such as car door rings , are manufactured in as a single piece through one hot-forming operation .
“ This makes for a rational manufacturing process with fewer operations ; simpler handling and logistics ; fewer tools ; better material utilisation and , therefore , lower production costs per unit . To further streamline production , each operation in the process has been analysed and optimised ,” AP & T explained . “ Our solution for hot forming of car body parts out of high-strength aluminium can result in weight savings of up to 40 per cent .”
High standards are put on tools used in sheet forming to ensure that body parts meet the required tolerances and to avoid the risk of cracks . Developing tools for the hot forming of highstrength aluminum is important in AP & T ’ s tooling operations . It has optimised the tribological behavior between tool surface and high-strength aluminum blanks by using the right combination of tool coating and lubricant .
ISMR December 2022 / January 2023 |
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