CPF
Center for Precision Forming
(www.cpforming.org)
Taylan Altan, Director (email: altan.1@osu.edu)
A short Review
July, 2011
Introduction
CPF
• The Ohio State University (OSU) and have established the
Industry/University Cooperative Research Center (I/UCRC) on
Precision Forming (CPF) focusing on research needs of metal
forming industry.
• Funding is provided by National Science Foundation (NSF) and
member companies.
• CPF (www.cpforming.org) benefits from research conducted at
Engineering Research Center for Net Shape Manufacturing
(ERC/NSM – www.ercnsm.org).
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Objectives
CPF
• Improve existing metal forming processes/products and develop new
innovative processes, tooling and equipment.
• Conduct projects in close collaboration with industry and transfer the
results to the member companies.
• Train and educate engineers in the fundamentals and practice of metal
forming science and technology.
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Current Members
• Aida- America Corp.
CPF
• Boeing
• EWI
•Honda
• ESI North America
• General Motors Corp.
• Interlaken Technology Corp.
• POSCO (Korea)
• IM Steel
• Scientific Forming Technologies (SFTC) Corp.
• IMRA America
• Metalsa
• JCI
• Thixomat
• Tyco
•Labein
•Cincinatti, Inc
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Current Projects
CPF
CPF 1.1: Elevated temperature stamping and hydroforming of Al, Mg and
Stainless Steel
Objective:
Develop guidelines for elevated temperature sheet forming (process optimization,
lubricant evaluation and Finite Element Modeling)
Warm deep drawing (in cooperation with AIDA Engineering, Ltd.)
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Current Projects
CPF
CPF 1.4: Investigation of springback in forming Advanced/High
Strength Steel (A/HSS)
Objectives:


Determine the variation of Young’s Modulus with deformation /strain
Predict and reduce springback in stamping A/HSS
Planned experiments (Tool concept)
1. Straight flanging
2. Stretch flanging
3. Shrink flanging
4. Straight hat shape drawing and stretching
5. Curved hat shape drawing and stretching
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Current Projects
CPF
CPF- 2.1: Determination of room temperature properties of Al and steel
sheet materials under biaxial conditions
Objective:
Develop a standardized tool design and procedure to determine flow stress,
anisotropy and formability under biaxial deformation
Sheet bulge test
(Viscous Pressure Forming –VPF)
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Current Projects
CPF
CPF- 2.2: Determination of flow stress of Al and Mg sheet materials at
elevated temperatures
Objective:
Determine flow stress of sheet materials at elevated temperatures for the warm
forming process.
Hole
Modified Limiting Dome Height
(MLDH) Test
Inverse Analysis Technique
Formed sample
(OD = 14in, t0 = 0.034in)
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Current Projects
CPF
CPF- 2.3: Investigation of tribological conditions in forming uncoated
and galvanized Advanced/Ultra High Strength Steels (A/UHSS)
Objective:
Determine the effect of process parameters (interface temperature, pressure and
relative sliding speed) on galling / reduce galling
Micrograph of galled surface
Tool surface
P
rm
A
T
Twist compression Test (TCT)
(in cooperation with IRMCO)
Galling
• Testing materials: DP 600 Bare with Lub A
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• Testing conditions: P = 170 MPa & N= 8.9 RPM
CPF
Current Projects
CPF - 4.1: Multi Point Control (MPC) die cushion and blank holder
technology in stamping
Objective:
Develop an automated system to optimize the Blank Holder Force for robust
stamping
Die
Blank holder /
Binder
Individual hydraulic
cylinders for each
cushion pin
Location of cushion pins/
cylinders in the die
(Source: Müller Weingarten)
Proposed system for robust stamping using MPC
(continue)
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Current Projects
CPF
CPF - 4.1: Multi Point Control (MPC) die cushion and blank holder
technology in stamping (continue)
Parts formed with OSU software by USCAR (try-out reduced from 3 days to 3 hours)
Al 6111-t4 (t = 1 mm)
BH210 (t = 0.81 mm)
DP500 (t = 0.78 mm)
Sample parts [GM lift gate inner panel] with different materials and sheet thickness was formed in
the same die by simply adjusting the BHF.
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Current Projects
CPF
CPF- 4.2: Applications of Tube Hydroforming (THF) Technologies
Objective:
Utilize past R&D experience at OSU to assist interested companies in
introducing and/or improving the hydroforming technology
A.
C.
B.
D.
General concept of Tube Hydroforming Process
(Hydroforming of the T-shape part)
[Leitloff , 1997 ]
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Center for Precision Forming CPF
(CP-Forming-www.cpforming.org)
New tasks under consideration
• Cold and Warm Hydroforming of Al and Mg alloys
• Simulation of Hot Stamping of Boron Steels
• Precision /Flashless Forging of automotive components (for example
tie rods, pinion gears and bevel gears)
• Prediction and reduction of residual stresses in machining and burnishing
(advanced FE analysis)
• Micro-stamping for electronic applications (lead frames, CD drive
components, etc.)
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