浦项汽车板EVI

POSCOEVIActivitiesAutomotiveSteelApplicationCenterTechnicalResearchLaboratoriesPOSCOPOSCOEVI1‰TechnicalpartnershipwithintegratedsolutionofsteelandapplicationtechnologyCustomerRequirementsofmaterialandpartsAuto.steelproduction.Optimumspecification.QualitycontrolPOSCOOptimummaterialandapplicationtechnologyASAC.Materialdevelopment.Partproposal9Databaseofautomotivesteelproducts9DevelopmentofintegratedSolutionandproposal9EVIsupportbasedonSE&CEPOSCOEVI2‰EVI(EarlyVendorInvolvement)•Win-WinStrategyforCustomerandPOSCO•FromStylingtoMassProductionStylingProtoDesignProd.DesignCarMaker’sProcessTestCarManufact./TestProtoBuild1TestProtoBuild2TestPilotDieDesign/Manufacture/TryoutEVIActivityStylingFixMaterialsData,FormingSimulation,MaterialsSelection,CostInformationMajorFixTesting&Evaluation,Materials-ProcessOptimizationMinorFixDieDevelopmentSupportSOPMaterialsInformationDetailedPropertiesforPartManufacture,TestMaterialsSupplyMaterialsQualityMonitoring3ˆStylingOEMPOSCOActivitiesPartdesignNozAvailableCADsystem•CATIAV5•Unigraphics•Pro-engineer•IGESformat•Partlists•PartCADdataMaterialProposalzMaterialinformation•Supplymaterialinformation-Availablematerialgrades-Mechanicalpropertiesforcrash,stiffness…..-Weldingconditions-PaintingconditionszOverviewoffeasibility•Proposesteelgrade&thickness-BasedonempiricalguidelinesAcceptance?•Targetweight&cost•Targetperformance(Crash,Stiffness,NVH)-Onestepsolver-MaterialDB•Proposenewformingtechnologies-TWB,HF,HPFYesReport&ProposalzAvailableone-stepsolver•Inhouses/w•Autoform•Fastform•Proposepartdesignchanges(optional)※OnHF&HPF,poscosupplyStylingfixthefinalproductsˆProtodesign4OEMPOSCOActivitiesStylingfixYesDesignchange?•Partlists•PartCADdataMaterialselectionzAvailableFEs/w•Pam-stamp•Dynaform•AbaquszDetailoffeasibility•Formingsimulations-Formability(crack,wrinkle…)-Process&diedesign-Materialchange-Partmodification•Weldability-Spot,arcweldingconditions•Paintability-Electrodeposition,phosphatingadhesion,corrosion•Designnewformingtechnologies-TWB:Layout(Blank,weldinglinedesign),diesurfacedesign-HF:PartdesignforHF,costanalysis-HPF:PartdesignforHPF,costanalysiszPrototypingassist•Samplesupply•Testing&evaluationNoNoAcceptance?YesReport&Proposal5ˆProtobuildOEMPOSCOActivitiesProtopartsReportPartorassemblypartPerformanceevaluationzPerformance•Static/dynamicdentability•Corrosiontest•Fatigue•Stiffness•Crashworthiness※Performanceevaluationsweredonebypartorassemblypart6MaterialMildsteelCHSP40ECHSP45EDP490DP590SPFH540TWBNo.54142412Appendix:Weight&CostreductionˆAHSSzModel:CommercialvehiclezProposedmaterialzRemark−Weightreduction:20%−Costreduction:7%PartnameInitialdesignProposalRemarkMaterialThicknessMaterialThicknessPANELBODYSIDEINNERLHSLPRW/OWINDOWD513,SS:4010SPCC1.0DP5900.8WeightreductionPANELBODYSIDEINNERRHSLPRW/OWINDOWD513,SS:4010SPCC1.0DP5900.8WeightreductionPANELDOOROUTERLHRHDIFHS400CHSP40E0.7DP4900.7Enhanceddentresistance7ˆTWB(TailorWeldedBlank)zReinf.Sideouter1.6t1.6t2.2t1.6t1.4t1.4t2.2t1.4t1.2t※Production:300,000car/5yearsConventional(%)TWB(%)(+/-)%PanelcostMaterialcost10076-24Toolcost10096-4Manufacturingcost100118+18Totalcost10083-17Blankweight10078-22ConventionalTWB(+/-)WorkingexpenseNo.Tools158-7(ea)Presslinesaving--$7.5-$7.5Joininglinesaving--$1.1-$1.18zDoorinner1.6t0.8t1.6t0.8t※Production:300,000car/5yearsConventional(%)TWB(%)(+/-)%PanelcostMaterialcost10092-8Toolcost10074-26Manufacturingcost10086-14Totalcost10088-12Blankweight10092-8ConventionalTWB(+/-)WorkingexpenseNo.Tools84-4(ea)Presslinesaving--$2.2-$2.2Joininglinesaving--$0.3-$0.39ˆHF(Hydroforming)zEnginecradleProcessSequenceBendingPressPreformingHydroformingProcessDesignBendDie(R=120mm)CAESimulationDieCostsPartCostsWeight60%20%30%9Noofparts:6→1Weight:15→8KgseriesproductionSchmitz&Brill,GermanyzExhaustManifoldNumberofindividualpartServiceLifeProductioncostDevelopmenttimeWeightconventionalhydroformingproductionFatigueAnalysis(ThermalShock)10HydroformingPart467ˆHPF(HotPressForming)zBumperImpactBeam46147045314752345612471460ConventionaldesignHPFdesign456Hardness,HVConventionaldesignHPFdesignRemarkWeight(Kg)8.8625.543Weightreduction:37.5%Penetrationdepth(mm)92.582.0Crashperformance:+11.4%11MainActivitiesinAutomotiveSteelApplicationCenter1.Materialdatabase2.Stamping3.Crashworthiness4.Welding5.Painting13MaterialDataBase‰MaterialDataSpecification/Microstructure/ProductionProcessTensileTest(Standard,HighStrainRate)/CrashworthinessFriction/FLD/HoleExpansionRatioSpotwelding/LaserweldingLowCycleFatigue/HighCycleFatiguePre-treatment/Adhesionproperties/Corrosion‰SupportforCustomersƒExperimentallyevaluatedmaterialdataaresuppliedƒMaterialdataforsimulationscanbeofferedƒFeasiblematerialsforeachautomotivepartcanbeselected14Activities–StampingPartdesign•Proposethematerialselection-Flowcurve,FLC,LDH,….-Highstrainrateflowcurve(~500/s)-Optimumweldingandpaintingconditions•ProposepartgeometrymodificationsTooldesign•Designthemanufacturingprocessandtoolconcept•DiefacedesignFormingsimulationPerformanceEvaluation•Formingsimulationanddesignmodification-Thinning,FLD