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Center for Precision Forming (CPF)

Status of CPF (members / projects)
(Update – August, 2009)

The following companies already joined (or in the process of joining) CPF:

AIDA-America Boeing ESI North America Edison Welding Institute General Motors IMRA America Interlaken IM steel / Daido I O M S JCI Labein National Science Foundation   SFTC

Based on interest from member companies, we are conducting the following projects:

CPF 1.1 Elevated temperature stamping and hydroforming (OSU and VCU)

This project was originally focused on warm forming of Al and Mg alloys and Stainless Steels. However, we will also spend some effort on room temperature hydroforming of steels and Al alloys.

Project Progress:

• Project plan (non-proprietary, please click here to review the FLASH file)
• Bimonthly and technical progress reports (available to members only)
• Bimonthly progress reports (July, Sept, Nov 2006)
• CPF-1.1/06/01, (ERC/NSM-04-R-35) Determination of the properties of AZ31-O magnesium alloy sheet at elevated temperatures using the hydraulic bulge test
• CPF-1.1/06/02, (ERC/NSM-06-R-01) Deep drawing of aluminum and magnesium sheets at elevated temperatures – comparison of finite element analysis and experimental result
• CPF-1.1/06/03, Warm deep drawing of round cups from Mg, Al, and SS – Non-isothermal FE simulations using Ls-Dyna
• CPF-1.1/06/04, (ERC/NSM-06-R-10) Flow stress database for aluminum and magnesium alloys for warm sheet forming
• CPF-1.1/06/05, (ERC/NSM-06-R-14) Experimental determination of drawability for Al 5754-O, Mg-AZ31B-O and SS304 at elevated temperature
• CPF-1.1/06/06, (ERC/NSM-06-R-16) Design of modified limiting dome height test used to determine the flow stress and friction coefficients of lightweight alloys at elevated temperature
• CPF-1.1/06/07, (ERC/NSM-06-R-01A) Experimental investigation of non-isothermal deep drawing of aluminum and magnesium sheet
• CPF1.1/07/01, Experimental and numerical investigation of non-isothermal deep drawing of aluminum and magnesium sheet - A summary report
• CPF-4.2b/06/01, (ERC/NSM-05-R-21) Estimation of optimal blank holder force and pressure trajectory in sheet hydroforming with punch (SHF-P) hydromechanical deep drawing (HDD).
• CPF-4.2b/06/02, (ERC/NSM-05-R-26) FE simulation of rectangular pan forming using sheet hydroforming process with die (SHF-D).
• CPF-4.2b/06/03, (ERC/NSM-05-R-30) Development of trunk lid outer by sheet hydroforming with punch (SHF-P).
• CPF-4.2b/06/04, (ERC/NSM-06-R-15) Development of decision making procedure for replacing conventional deep drawing process with sheet hydroforming process with punch (SHF-P).
• CPF-4.2b/07/01, Summary report: Sheet hydroforming with punch (SHF-P) process
• CPF-4.2b/07/02, Sheet hydroforming with punch (SHF-P) process of large / deep parts with surface features
• CPF Report- Project 1.1- 2007 01: A Study on Warm Hydroforming of Al And Mg Sheet Materials: Validation Analyses and Optimal Temperature Conditions, H. Choi, M. Koç (VCU).
• CPF Report- Project 1.1- 2007 06: Determination of Optimal Loading Profiles in Warm Hydroforming of Lightweight Materials, H. Choi, M. Koç (VCU).
• CPF Report- Project 1.1- 2007 10: A study on the analytical modeling for warm hydro-mechanical deep drawing of lightweight materials, H. Choi, M. Koç (VCU).
• CPF-1.1/08/01 Determination of Flow Stress for Aluminum AA5754-O at Room Temperature using the Hydraulic Bulge Test at General Motors R&D
• CPF 1.1/08/02, Warm Deep Drawing of Round Cups from Aluminum Alloy AA5754-O, Magnesium Alloy AZ31B-O and SS304 - Non-Isothermal FE Simulations using PAM-STAMP 2G
• CPF 1.1/08/03, Room Temperature Sheet Hydroforming with Punch (SHF-D) of Axisymmetric Parts
• CPF-1.1/08/04 Methodology for Flow Stress Determination Using Biaxial Sheet Bulge Test Using Commercial FEM Code LS-DYNA & Optimization Tool - Part 1: Flow Stress at Room Temperature

CPF 1.2  Opportunities for impulse methods in sheet metal fabrication

This project will start as soon as we have new members interested in this research topic

CPF 1.3  Investigation of formability and quality issues in fabrication of A/UHSS components. (VCU)

A project plan and a bimonthly progress report have been prepared.

• Bimonthly and technical progress reports (available to members only)
• CPF Report- Project 1.3- 2006 12: Simulation of springback variation in forming of advanced high strength steels, P. Chen, M. Koç (VCU).
• CPF Report- Project 1.3- 2007 06: Experimental investigation of springback variation in forming of high strength steels, P. Chen, M. Koç (VCU).
• CPF Report- Project 1.3- 2007 11: Investigation of formability, springback variation and quality issues in fabrication of A/UHSS components.

CPF 1.4 Control of springback and dimensional tolerances in forming advanced high strength steel (A/HSS) parts - (including the variation of E-modulus with deformation). (OSU)

• Project plan (non-proprietary, please click here to review the FLASH file)
• Bimonthly and technical progress reports (available to members only)
• CPF-1.4/07/01, Forming of advanced high strength steels (AHSS)
• CPF-1.4/07/02, Determination of Elastic Modulus at Loading and Unloading for Sheet Materials in Tensile Test
• CPF-1.4/07/03, Design of Tooling for Springback Studies in Forming AHSS Steels

 

CPF 2.1 Determination of room temperature material properties (flow stress, formability, anisotropy) of sheet materials under biaxial conditions. (OSU)

This project is essentially completed. We are assisting interested CPF members in implementing project results.

Project Progress:

• Project plan (non-proprietary, please click here to review the FLASH file)
• Bimonthly and technical progress reports (available to members only)
• Bimonthly progress reports (July, Sept, Nov 2006)
• CPF-2.1/06/01, (ERC/NSM-00-R-15) Evaluation of formability and determination of flow stress curve of sheet metals with hydraulic bulge test.
• CPF-2.1/06/02, (ERC/NSM-05-R-45) Determination of flow stress and anisotropy coefficients of sheet materials from biaxial test.
• CPF-2.1/06/03, (ERC/NSM-06-R-04) Determination of flow stress and formability of magnesium alloy sheet material AZ31B at room temperature using Viscous Pressure Bulge Test.
• CPF-2.1/06/04, (ERC/NSM-06-R-19) Selection of Test Method (Tensile Test, Bulge Test) to Determine Material Properties of Sheet Materials for Process Simulation.
• CPF-2.1/07/01 Summary Report - Flow Stress determination and formability estimation in sheet materials using the bulge test
• CPF-2.1/09/01 Determination of Flow Stress of Five AHSS Sheet Materials (DP600, DP780, DP780CR, DP780HY, and TRIP780) Using the Uniaxial Tensile Test and Biaxial Viscous Pressure Bulge Test

CPF 2.2a Determination of flow stress of Al and Mg sheet materials and friction at elevated temperatures using the LDH test (OSU)

This project will focus on Al & Mg alloys at elevated temperatures (150-300 C)

Project Progress:

• Project plan (non-proprietary, please click here to review the FLASH file)
• Bimonthly and technical progress reports (available to members only)
• Bimonthly progress reports (July, Sept, Nov 2006)
• CPF-2.2a/07/04, Simultaneous Determination of Flow Stress and Friction Coefficient in Sheet Metal Forming – Development and Application of Modified Limiting Dome Height (MLDH) and Limiting Dome Height (LDH) Test

 

CPF 2.2b Determination of flow stress of sheet materials at elevated temperatures using hydraulic bulge testing. (VCU)

A project plan and the first bimonthly report are issued.

• Bimonthly and technical progress reports (available to members only)
• CPF Report- Project 2.2b- 2007 10: Investigations on Mechanical Behavior of Aluminum 5052 and 6061 Sheet Alloys at Elevated Temperature Hydraulic Bulging Conditions, S. Mahabunphachai, Y. Usta, M. Koç (VCU).
• CPF Report- Project 2.2b- 2007 11: Determination of Lightweight Alloy Sheet Properties at Elevated Temperatures Using Hydraulic Bulge Test
• CPF Report- Project 2.2b- 2008 12: An Experimental Comparative Study on Hydraulic Bulge Analysis Methods
• CPF Report- Project 2.2b- 2009 1: Warm Hydroforming Characteristics of Austenitic Stainless Steel Sheet Metal Alloys
• CPF Report- Project 2.2b- 2009 2: Material Behavior and Formibility of Magnesium AZ31 Sheet Alloy Under Warm Hydroforming Conditions

CPF 2.3  Investigation of tribological conditions in forming uncoated and galvanized advanced / ultra high strength steels. (OSU)

This project will be focused on (a) evaluating and developing new lubricants and additives (and friction) and (b) galling and tool wear (how to reduce it).

Project Progress:

• Project plan (non-proprietary, please click here to review the FLASH file)
• Bimonthly and technical progress reports (available to members only)
• Bimonthly progress reports (July, Sept, Nov 2006)
• CPF-2.3/06/01, Investigation of tribological conditions in forming uncoated and galvanized advanced/ultra high strength steels – A literature review
• CPF-2.3/06/02, (ERC/NSM-05-R-13) Evaluation of lubricant performance in cold forging operations and fundamental study of the double cup extrusion test
• CPF-2.3/06/03, (PF/ERC/NSM-04-R-28) Investigation of the effect of temperature on lubrication and flow stress in cold forming using the ring compression test
• CPF-2.3/06/04, (PF/ERC/NSM-04-R-21) Micro-tribology for metal forming – A literature review
• CPF-2.3/06/05, Evaluation of stamping lubricants using the deep drawing test
• CPF-2.3/06/06, (ERC/NSM-05-R-06) Performance evaluation of dry film lubricants at various temperatures using ironing tribotest
• CPF-2.3/06/07, Determination of Critical Interface temperature and Pressure for Initiation of Galling by Using the Finite Element (FE) Analysis
• CPF-2.3/07/01, Investigation of galling in forming galvanized AHSS - Second progress report: Twist compression test of galvanized AHSS
• CPF-2.3/07/02 Investigation of galling in forming galvanized AHSS- Third progress report: Evaluation of deep drawing performance of various stamping lubricants with DP 590GA
• CPF-2.3/07/03, Investigation of Galling in Forming Galvanized Advanced High Strength Steels (AHSS), Fourth Progress Report: Evaluation of Stamping Lubricants in forming AHSS Using Deep Drawing and Ironing Test
• CPF-2.3/08/01, Investigation of Galling in Forming Galvanized Advanced High Strength Steels (AHSS), Fifth Progress Report: Evaluation of Stamping Lubricants and Tool Materials Using the Twist Compression Test
• CPF-2.3/08/02, Investigation of Galling in Forming Galvanized Advanced High Strength Steels (AHSS), Sixth Progress Report: Evaluation of Die Coatings and Stamping Lubricants using the Strip Drawing Test
• CPF-2.3/08/03, Investigation of Galling in Forming Galvanized Advanced High Strength Steels (AHSS), Seventh Progress Report: Evaluation of Die Coatings using the Strip Drawing Test
• CPF-2.3/09/01, Tool Wear in Stamping of Advanced High Strength Steels (AHSS) - A Review

CPF 2.4 Development of die wear testing method and apparatus for cold and warm forming of light weight materials. (VCU)

A project plan and the first bimonthly report are issued.

• Bimonthly and technical progress reports (available to members only)
• CPF Report- Project 2.4- 2007 08: Investigations on the feasibility of a rapid die wear method and apparatus, O. N. Cora, Y. Usta, M. Koç (VCU).
• CPF Report- Project 2.4- 2007 10: Experimental Investigations on Wear Resistance Characteristics of Alternative Die Materials for Stamping of Advanced High Strength Steels (AHSS), O. N. Cora, Y. Usta, M. Koç (VCU).
• CPF Report- Project 2.4- 2007 11: Development of Die Wear Test Method and Apparatus
• CPF Report- Project 2.4- 2008 12: Wear Performance Assesment of Alternative Stamping Die Materials
• CPF Report- Project 2.4- 2009 01: Influence of Substrate Material on Wear Performance of Stamping Dies Utilizing a New Die Wear Test System

Project 2.5: Evaluation of Lubricants for Improving Stamping Quality (new project / OSU)

• CPF-2.5/09/01, Evaluation of Stamping Lubricants to Improve Stamping Quality - Part I.
• CPF-2.5/09/01-a, Evaluation of Stamping Lubricants to Improve Stamping Quality - Progress Report -- 2 (April 2009)

CPF - 3.1, Micro/nano-engineered functional surfaces for fuel cell, heat & mass transfer applications (new project / VCU)

Project 3.2: Micro/nano-engineered surfaces for advanced heat transfer and fuel cell applications. (VCU)

• Bimonthly and technical progress reports (available to members only)
• CPF Report- Project 3.2- 2006 06: Modeling of the semi-solid material behavior and analysis of micro/meso-scale feature forming, G.Y. Kim, M. Koç (VCU).
• CPF Report- Project 3.2- 2006 10: Experimental investigations for fabrication of micro-scale features on semi-solid substrates, G.Y. Kim, M. Koç (VCU).
• CPF Report- Project 3.2- 2007 11: Experimental and Numerical Investigations on Micro-Coining of 304 Stainless Steel, G.Y. Kim, M. Koç (VCU).
• CPF Report- Project 3.2- 2007 01: Feasibility Investigations on Manufacturing of Micro-Scale Porous Surface Structures, P. Chen, M. Koç (VCU).
• CPF Report- Project 3.2- 2007 05: Modeling of the Size Effects on the Behavior of Metals in Micro-Scale Deformation Processes, G.Y. Kim, M. Koç (VCU).
• CPF Report- Project 3.2- 2007 06: Feasibility Investigations on a Novel Micro-Manufacturing Process for Fabrication of Fuel Cell Bipolar Plates: Internal Pressure-Assisted Embossing of Micro-Channels with in-Die Mechanical Bonding, S. Mahabunphachai & M. Koç (VCU).
• CPF Report- Project 3.2- 2007 09: Characterization of pressure welding process of thin sheet metals in cold and warm temperature conditions, S. Mahabunphachai & M. Koç (VCU).
• CPF Report- Project 3.2- 2007 10: Fabrication of Micro-channel Arrays on Thin Metallic Sheet Using Internal Fluid Pressure: Investigations on Size Effects and Development of Design Guidelines, S. Mahabunphachai & M. Koç (VCU).

CPF - 3.3, Process Development for robust fuel cell bi-polar and interconnect plate fabrication (new project / VCU)

CPF 4.1 Practical use of multi point control (MPC) die cushion technology in production of stamped parts. (OSU)

This project will develop, for a given part, an automated system to a) predict the necessary number and location of cushion pins and b) adjust the force on each pin using a flange imaging system for feed back.

During the last 3 years, as part of a USCAR project, OSU developed software to program a MPC cushion system. We are now planning to expand this technology to practical application. A project plan and a quarterly report are available

Project Progress:

• Project plan (non-proprietary, please click here to review the FLASH file)
• Bimonthly and technical progress reports (available to members only)
• CPF-4.1/07/01, (S/ERC/NSM-07-R-22) Estimation of Optimum Process Parameters in Sheet Hydroforming a Rectangular Part
• CPF-4.1/08/01, Programming Multipoint Blank Holder Force System to Form Retractable Hard Top Inner From Sheet Material AA6016-T4

 

CPF 4.2 Tube hydroforming (THF) - Advanced features and applications (tube quality, lubrication, simulation). (OSU)

This project will utilize past R&D experience that is available at OSU and will assist interested companies in (a) the evaluation of tube quality and properties to reduce scrap, (b) the evaluation of lubricants and (c) FEM simulation of the THF process.

Project Progress:

• Project plan (non-proprietary, please click here to review the FLASH file)
• Bimonthly and Technical Progress Reports (available to members only)
• Bimonthly Progress Reports (July, Sept, Nov 2006)
• CPF-4.2a/06/01 (THF-ERC/NSM-04-R-30) “Determination of biaxial formability and flow stress for low carbon steel tubing”
• CPF-4.2a/06/02 (THF-ERC/NSM-99-R-09) “Prediction of tubular material properties for aluminum alloy 6260-T4”
• CPF-4.2a/06/03 (THF-ERC/NSM-03-R-27) “Hydraulic bulge tooling to determine the properties of tubular materials”
• CPF-4.2a/06/04 (THF-ERC/NSM-04-R-31) “Advanced methods for Finite Element simulation for process design in tube hydroforming”
• CPF-4.2a/06/05 (THF-ERC/NSM-00-R-07B)“ Evaluation of metal flow in tube hydroforming Y-Shapes: experiment and simulation results"
• CPF-4.2a/06/06 (THF-ERC/NSM-02-R-27B) “Bending and tube hydroforming of a structural part”
• CPF-4.2a/06/07 (THF-ERC/NSM-00-R-08) “Evaluation of tube bending experiments: effects on design parameters in rotary draw bending process”
• CPF-4.2a/06/08 (THF-ERC/NSM-04-R-37) “Determination of loading path and sensitivity analysis of isothermal tube hydroforming of magnesium alloy AZ31B at elevated temperatures”

 

CPF 5.1 Evaluation of bendability of AHSS. (new project / OSU)

• CPF-5.1/08/01, Fracture in Stretch Bending Advanced High Strength Steels (AHSS), A Literature Review and an Attempt to Predict Fracture
• CPF-5.1/09/01, Wedge Bending Test to Evaluate the Bendability of Advanced High Strength Steels (AHSS)- Progress Report
• CPF-5.1/09/02, Stretch Bending for Advanced High Strength Steels(AHSS)- A Finite Element Analysis

CPF 5.2 Prediction and elimination of edge cracking of AHSS in stretch flanging. (new project / OSU)

• CPF-5.2/08/01, Finite Element Modeling of Blanking and Hole Expansion for AISI 1050 Steel, Results of Experimental and Numerical Investigations
• CPF-5.2/08/02, Simulations of Blanking and Hole Flanging Test for Advanced High Strength Steel DP590
• CPF-5.2/09/01, Development of a Methodology to Predict Edge Cracking of Advanced High Strength Steels (AHSS) - FEM Simulations and Use of Fracture Criteria

CPF 5.3 Development of a die wear test for trimming / cutting / blanking dies. (new project / VCU)

CPF 5.4 Warm hydroforming of engineered blanks Al, Mg, Ti & AHSS. (new project / VCU)

CPF 5.5 Hot stamping of boron steels. (new project / OSU)

• CPF-5.5/08/01, Hot Stamping of Ultra High Strength Steels- A State of the Art Review

CPF 5.6 Applications of Servo-Drive Presses in Stamping. (new project / OSU)

• CPF-5.6/08/01, Application of Servo-Drive Presses in Stamping
   

Quarterly progress reports are given in “Members only” section that can be accessed by user name and password, available only to CPF member companies
 

• Technical reports can be requested (by CPF members) from Taylan Altan, Director (Email: altan.1@osu.edu, phone: 614-292-5063) or from Muammer Koc, Co-Director (Email: mkoc@vcu.edu, phone: 804-827-7029)