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Data classification: Internal 3/25/2013Shiloh Industries, Inc.
Forming Challenges for Mass Optimization
Shiloh Industries, Inc.March 21, 2013
Cliff Hoschouer, Steve Fetsko, Jim Evangelista, Mike Telenko
Shiloh Engineering and Technology
Geographic Locations
Medina Blanking
OH, USA
Engineering, Blanking,
EWB, Laser Cutting
Liverpool Coil Processing
OH, USA
Coil processing, Stamping,
Modular Assembly,
AcroStikTM
Ohio Welded Blank
OH, USA
Blanking, EWB,
Bowling Green Manufacturing
KY, USA
Heavy Gauge Blanking,
Stamping
Jefferson Manufacturing
GA, USA
Blanking, EWB, Stamping
Wellington Manufacturing
OH, USA
Complex Stamping,
Modular Assembly
Canton Manufacturing;
Sales &Technical Center,
MI, USA
Engineering, Blanking, EWB,
Stamping, Modular Assembly
Shiloh de Mexico
Ramos Arizpe, Mexico
Blanking, EWB, Stamping,
Modular Assembly
AcroStikTM
Albany-Chicago Company
Aluminum Die Casting
Dickson Manufacturing
TN, USA
Complex Stamping,
Modular Assembly
Our Customers
Product Applications
4
Outline
• Current Forming Challenges
– Advanced High Strength Steel (Trip 780)
– Engineered Welded Blanks
• What are the future forming challenges?
– Aluminum Forming
• Including welded blanks
3/25/2013 5
Within
Current Challenges
• Advanced High Strength Steel
– Challenges for forming
• Material variability
• Material edge failures
– Possible forming solutions
6
To
3/25/2013 7
Advanced High Strength Steel
• Material Variability Within Coil: Trip 780
Master coilRight hand part failures
Slit line
2 out Progressive Die
Left hand part failures
Width of master coil
Left Side Coil Right Side Coil
Advanced High Strength Steel
• Material Variability: Trip 780
8
Hole Expansion test to help determine edge cracking
22.5% Strain = 10.6% thinning
Target: 14.7% Strain = 7% thinning
12.2% Strain = 5.7% thinning
Advanced High Strength Steels
9
Edge Cracking Issues
� 780 trip Steel
� Standard Blanking
Zone A
Zone B
Purple (current blank)
Blue (run 3 blank)
Green (run 3A blank)
10
Advanced High Strength Steels
• Possible Solution for Zone A
Advanced High Strength Steel
11
• Possible Solution for Zone B
Partially filled in zone
“B”
Advanced High Strength Steel
Small rib added to lower
tooling
12
• Possible Solution for Zone B
Patent Pending
Advanced High Strength Steel
Small rib Zone A in blank
13
• Possible Solution for Zone A
Patent Pending
Advanced High Strength Steel
14
Summary
• Key is to relieve stress on the edge of the
part
–Adding material to the outside of the blank
–Placing features in the die/blank to relieve
stress on the outside edge
Current Challenges
• Engineered Welded Blanks Challenges
– Lack of curvilinear knowledge in the industry
(perceived costs and benefits not understood)
– Adjusting joining line according to product
requirement for mass optimization
– Adjusting joining line for improved formability
15
16
Base Design Curvilinear Weld Option
Blank Gauge in mm
Mass in kg
Thick Blue 1.80 4.75
Thin Green 0.80 4.59
Total 9.34
Blank Gauge in mm
Mass in kg
Thick Pink 1.80 2.75
Thin Brown 0.80 5.48
Total 8.23
-1.11 Kg /Door
Mass Savings
Vehicle Mass OptimizationCase Study for HEV Door Inner
Engineered Welded Blanks (EWB)
Balance - Formability & Mass Savings
Engineered Welded Blanks (EWB)
17
Engineered Weld Blanks
18
Summary
• Curvilinear blanks typical have NO cost
penalty compared to a linear welded
blank
• Welded Blanks can improve formability
while reducing on vehicle mass
• Reduce cost of introducing more
expensive light weight materials
3/25/2013 19
• Multi-piece Aluminum
• Monolithic Aluminum
• Aluminum Welded Blanks
Aluminum Forming
• Challenges
– Lack of experience and difficulty in finding specific aluminum data
– Reduced formability due to material properties
• R-values < 1
• Work hardening
• Possible forming solutions
3/25/2013 20
How is aluminum forming different?
3/25/2013 21
Over 90% thinning 2 inches from bottom
What needs to change?
3/25/2013 22
BOTH
Or The Product?The Dies?
Example of Aluminum vs. Steel
• Prototype 3 piece welded blank fender inner.
Die was developed for steel utilizing linear
laser welded blanks. Die is now available for
Aluminum development trials.
• Completed modification of die for Aluminum
based on formability studies.
• Fabrication of Aluminum parts:
3/25/2013 23
1mm2mm
2mm
3/25/2013 24
AL in original steel tool – Thinning
Thinning :
Target < ?
Max. (82.9%)
34.3%
82.9%
31.1%
31.6%
Weld line locations
Changes to the die are needed
3/25/2013 25
Area removed from die
Steel Die
Aluminum Die
3/25/2013 26
Aluminum Forming Simulation
Aluminum Material Joining
3/25/2013 27
Friction Stir Welding• Solid state welding process,
• no material melting,
• retains original material properties
• Slower process than laser welding
• Extremely high fixturing and processing forces
require
• Successful AWS D1.2 tensile test
• Successful AWS B4.0 bend test
• Robotic end effector FSW head
• Potentially different FSW tooling for every
material grade and thickness combination
Laser Welding
• Adjust parameters to develop weld
characteristics:• Filler wire vs. autogenous
• Shield gas vs. no shield gas
• Root and crown shielding
• Successful ASTM E 8 tensile test
• Formability trials in process
Aluminum Forming Simulation
3/25/2013 28
Thinning :
Target < ?
Max. (26.0%)
Weld line locations
EWB aluminum Fender
3/25/2013 29
2mm
2mm
Laser Weld forming of Aluminum
3/25/2013 30
Summary
31
• Advanced High strength steels will continue to
be challenging for the next 5 years
• Curvilinear Welded Blanks can provide needed
on vehicle mass reduction now and in the
future
• Aluminum Is Coming!!
32
Jim Evangelista
Director Technology & Business Development
Shiloh Industries
734-354-3139
Cliff Hoschouer
Engineering Analyst
Shiloh Industries
330-558-2323
Steve Fetsko
Engineering Analyst
Shiloh Industries
330-558-2336
