Gestamp-Experience of VANADIS 4

Cold Forming & UHSS for lightweight steel applicationsFebruary 2004

Tier 1 supplier for automotive components and modules

GESTAMP AUTOMOCION

Tooling

R&DCommercial office

Big Stamping

HydroformingTailored Blanks

Protection

Assembling & Systems Small & Medium Stamping

Year 2003: 1250 M turnover

GESTAMP AUTOMOCION: Centers R&D

4 Centres R&D Abadiano (Spain)

Abrera (Spain)

Westerburg (Germany)

Meudon ( France )

Staff 56 Employees in R&D activities.

Simultaneous Research with Universities and Technical Centers :

( CTM; CASTMOLD; LABEIN; IFU; IDIADA)

( ROBOTIKER; INASMET; CIDAUT; CTAG )

GESTAMP AUTOMOCION: R&D Activities

Product Development Pedal Assembly, Mobile Parts, Subframes, Axles,Instrument Panel Beam,Bumper Beam Systems, others .

Advanced Technologies Development

Hydroforming, Tailored Blank, Hot Stam

Patchwork, Laser Welding, ping, Roll Forming, HSS Stamping, New materials

Advanced Technologies Research

Die Casting Magnesium; Aluminium; others ..

Co-Development with the Customer VW / SEAT; OPEL / FIAT; FORD;PSA; RENAULT / NISSAN ;

ENGINEERING SERVICES

LASER WELDED TAILORED BLANKS

BLANKING

TOOLING

HYDROFORMINGSTAMPING

PROTECTION

MODULE ASSEMBLY

Total collaboration with our customersStarting from the concept and development phase we offer to our customers our project teams and simultaneous engineering service controlling all the value chain, supplying all our know-how together with all our experience in the different technologies and responsibilities through the whole production process.

VALUE CHAIN

R&D. PRODUCT DEVELOPMENT

Dashboard crossmember

Engine subframe

Pedal boxes

Rear bumper module

Outer panels

Vehicle systems

Front bumper module

Hood

R&D. TECHNOLOGIES

Roll FormingTooling Cold/Hot Forming

Hydroforming

ProtectionTailored Welded Blanks

Laser welding Patchwork

HYDROFORMING

Rp0.2%=180MPa RM=500MPaMild High Strength Steel HSS

Steel

Ultra High Strength Steel UHSS

RM =1400MPa

100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400

IF

P & BH

Microalloyed

CURRENT INDUSTRIAL PRODUCTION

Dual Phase

TRIP

DESIGN & PROTOTYPING

R&D Project HYDROFORMING

HSS Tube Hydroforming

HSS Tube Preforming

HSS Tube Bending

High Strength Steel Tubes try-outs:HSS Engine cradle validation

Prototyping trials on February 2003

Prototyping Hydroforming tubes trials for Chassis application by the usage of HSS :

- Dual Phase 600

Product innovation and Processes Synergy

Tube dimensions : 60 x 2 x 2240 mm.

Processes :

Tube Bending by 2 steps

Tube Preforming by press of 450 Tn

Tube Hydroforming by press of 5000 Tn

No high Spring back effect at the end tube

1,5mm spring back at the ends tube by the

usage of DP600 material.

HYDROFORMINGInstrument Panel Beam

Gestamp trials on March-April 2004.Prototyping Hydrofoming tubes trials for Instrument Panel application by the usage of HSS.Trials with same material from different suppliers.

Product innovation and Processes SynergyTube dimensions : 73 x 1 x 1300 mm (DOCOL 600 DL)

73 x 1 x 1300 mm (DP600)Processes :Tube Preforming by hydroforming press of 3500 Tn (600bar). With axial feeding.Tube hydroforming by press of 3500 Tn (1600bar).

ROLL FORMING + BENDING

Rp0.2%=180MPa RM=500MPa

Mild High Strength Steel HSS Ultra High Strength Steel UHSS

RM =1400MPa

100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400

Microalloyed


Dual Phase

TRIP

Complex Phase

Martensitic Steel


TOOL 1: PUNCHING/CUTTING

TOOL 3.-PUNCHING/CUTTING ON FINAL PIECE

TOOL 2.- ROLL FORMING

Roll Forming lines at Gestamp Automocin

9 Up to 20kW9 Modular design

TOOL 4.- TWISTING STAND

ROLL FORMING: PROCESS

ROLL FORMING: PROCESS

Roll Forming: flat sheet formed into a profile by successive folding operations

Decoiling Straightening Roll Forming Auxiliary operations

Roll Forming ToolRoll Forming Flower

PRODUCTS

Side rails

Waist Reinforcement

Floor cross member

Roof cross member

Front bumper

Rear bumper

DP 1000 1.5 mm

A-pillar

ROLL FORMING + BENDINGROLL FORMINGComplexity

Front bumper

Rear bumperFront bumper

Rear bumper

Geometry

1D open profile

1D closed profile

2D open profile constant radius

2D open profile non-ct radius

2D close profile non-ct radius

2D close profile ct radius

HOT STAMPING

Usibor 1500P


Mild

IF

P & BH

Microalloyed

High Strength Steel HSS

Dual Phase

TRIP

Complex Phase

Martensitic Steel

Ultra High Strength Steel UHSS

RM =1400MPa

100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400

Ferritic-Bainitic

HOT STAMPING

USIBOR 1500 Pafter Heat TreatmentProperties in-use

USIBOR 1500 Pafter Heat TreatmentProperties in-use

Yield Strength

(MPa)

Ultimate Tensile Strength (MPa)

300 500 700 900 1100 1300 1500 1700

900

800

700

600

500

400

300At delivery

1400

1300

1200

1100

1000

Forming Properties

Yield Strength

(MPa)

Ultimate Tensile Strength (MPa)

300 500 700 900 1100 1300 1500 1700

900

800

700

600

500

400

300At delivery

1400

1300

1100

1000

Forming Properties

HOT STAMPING: PROCESS KNOW-HOW

HEATING PROCESS: time, temperature

COOLING PROCESS: cooling rate

COMPARISON BETWEEN STANDARD GRADE (S355) AND USIBOR 1500P

HOT STAMPING: PROCESS KNOW-HOW

V85= 20 C/s. 424 HV1 V = 30 C/s. 437 HV1 V = 40 C/s. 462 HV1

2 mm

6 m ~ 600 HV

-20-22 m ~ 60 HV

~ 170 HV200g

USIBOR 1500

2 mm

~ 170 HV200g

Pre-coatingPre-coating

USIBOR 1500P

HOT STAMPING: PROCESS KNOW-HOWThe conception of the bumper has been realized by GESTAMP (sizes, thickness, shape,)

Dies manufacturing done by Gestamp-Araluce

First prototypes: January 2003MATERIAL : USIBOR 1500

Yield strength: 1060MPa

Tensile strength: 1500 MPa

El %: 5

Thickness : 2,5mm

BLANKHOLDER PRODUCTION OVEN: 20C 950 C

600 t HYDRAULIC PRESS (by blank)

SUPERVISION

150 m2 FOR PRODUCTION LINE

WATER COOLED TOOL

BLANKHOLDER PRODUCTION OVEN: 20C 950 C

600 t HYDRAULIC PRESS (by blank)

SUPERVISION

150 m2 FOR PRODUCTION LINE

WATER COOLED TOOL

LWTB, PATCHWORK

Rp0.2%=180MPa RM=500MPaMild High Strength Steel HSS Ultra High Strength Steel UHSS

RM =1400MPa

100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400

IF

P & BH

Microalloyed

Dual Phase

TRIP

Complex Phase

Ferritic-Bainitic


Usibor 1500P

PROTOTYPING

LWTB, PATCHWORK

CPW800 2.25 mm

CPW800 3.0 mm

StO7 1,65 mm

St070,90 mm

COLD STAMPING


Mild High Strength Steel HSS Ultra High Strength Steel UHSS

RM =1400MPa

100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400

IF

P & BH

Microalloyed

Dual Phase

TRIP

Complex Phase

Ferritic-Bainitic


Martensitic Steel


MANUFACTURING PLANTS

Production Plant of H.S.S. Parts: Production Plant of H.S.S. Parts: MB.MB.SantpedorSantpedor ( Spain )( Spain )

Four Transfer Presses:1 Rovetta 2400 tn year 20011 Fagor 1500 tn year 20032 Arisa 1250 tn year 1998 - 1999

HSS Area

MANUFACTURING PLANTS

HSS Stamping Area

Welding Area

Production/Welding Plant of H.S.S. Parts: Production/Welding Plant of H.S.S. Parts: MB.MB.AbreraAbrera ( Spain )( Spain )

Press Line G2: ( year 2001 )1 Rovetta 2000 tn5 Weingarten 800 tn1 Krupp 1600 tn

HIGH STRENGTH STEEL PARTS

High Strength Steels Parts manufactured in Gestamp Group: High Strength Steels Parts manufactured in Gestamp Group:

Door ReinforcementDoor Reinforcement8 parts

2 parts in DP780 (1.35/1.25)1 part in TRIP800 (1.35mm) 1 part in DOGAL800 (1.35)2 part in DP600 (1.35mm) 2 part in DP450 (1.0mm)



Rail Side ReinforcementRail Side Reinforcement3 parts

1 part in DP600 (1.2 mm)2 parts in DP450 (1.6 mm)


6 parts

2 parts in CPW800 (3/2mm) 2 parts in TRIP800 (1.5/2mm) 1 part in DP500 (2mm)1 part in DP450 (1.75mm)


B Pillar ReinforcementsB Pillar Reinforcements

HIGH STRENGTH STEEL PARTS:DESIGN

Stamping process (TRIP800): Big addendum, big blank shape, in order to avoidspringback.

Avoid warping designs


Avoid Cam trimming: Maintenance very expensive!

Scrap material

Cam trimming

Drivers Binder

Cam Piercing & Trimming

Cam Piercing & Trimming


Gradual shape transitions and Open Ends (to reduce press force)

Gradual shape transitions

Open End Good for HSS.


The minimum die over bend for springback compensation depends on the tensile strength of the steel & on the thickness:Less thickness more springback, more tensile strength morespringback!!.

DRAWING DIES: NEW MATERIALS

The drawing die must be stronger, well guided, with The drawing die must be stronger, well guided, with better materials and coated (PVD or CVD).better materials and coated (PVD or CVD).

Die 1.2379 / 1.2382VANADIS 10 (CVD)

Binder 1.2379 (D2) (CVD)

Punch 1.2314 (GP4M)

TRIMMING DIES: NEW MATERIALS

The trimming die must be very well set up, with better The trimming die must be very well set up, with better materials and, in some cases, coated (PVD).materials and, in some cases, coated (PVD).

Trimming tool support 1.2379 / 1.2769

Binder 1.2379 (D2)

Trimming tool VANADIS 4

R&D. TECHNOLOGIES

Trimming & Drawing Dies for HSS: Powder metallurgical Trimming & Drawing Dies for HSS: Powder metallurgical steels (steels (UddeholmUddeholm).).

DIES FOR HSS:NEW MATERIALS

Breaks in the trimming dies (mainly in cam trimming): Breaks in the trimming dies (mainly in cam trimming): 1.2379 Steel (D2) (This steel is not enough ductile).1.2379 Steel (D2) (This steel is not enough ductile).

DIES FOR HSS:NEW MATERIALS

The new trimming dies: VANADIS 4 ( Breaks appear 4 The new trimming dies: VANADIS 4 ( Breaks appear 4 -- 6 6 times later that with 1.2379).times later that with 1.2379).

PVD

Gestamp-Experience of VANADIS 4

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