 | | | | | | | Corus has published a number of technical papers relating to the automotive industry | |
| | The application of simulation models in sheet metal forming in the automotive industry has proven to be beneficial to reduce tool costs at the designing stage and for optimising current processes. Moreover, it is a promising tool for a material supplier to optimise material choice and development for both its final application and its forming capability. The present practice requires a high predictive value of these simulations. A first stage is to implement the improved material models which describe this single strain path behaviour in a better way. Results are compared with predictions using Marciniak-Kuczinsky-analysis with both the new material model and the conventional material model. Finally, the validation on real pressed products is shown by comparing simulation results using different material models with the experimental data. The test required to measure the required material data are described in this conference paper.
|
|
| | When a metal is formed, its material properties change compared to the virgin 'as delivered' material. These changes can have an important effect on the performance of the resulting part in service. Corus has developed advanced techniques to incorporate the new material properties resulting from forming operations into CAE models that predict e.g. Crash or Fatigue behaviour. Presented at the LS-DYNA conference.
|
|
| | Dupla™ a newly developed steel from Corus is a ferrite plus martensite dual phase cold heading steel developed to take costs out of the high strength fastener manufacturing process. Tight composition, process and microstructural control provide a consistent rod product that requires neither spheroidisation annealing nor quench & temper heat treatments.
The required strength levels are achieved by drawing to size, with cold heading performed on the as-drawn wire. The formability and achievement of high strength product specifications have been demonstrated on a variety of fastener designs.
|
|
| | Corus Engineering Steels (CES) produces approximately 1.5MTpa of engineering steel, over half of which is consumed by the automotive industry, through its associated supply chains.
Two of the most significant drivers in the automotive component sector are weight and through-cost reduction. Forged engineering steels face increasing challenges to their dominant role in the automotive engine, transmission and suspension sectors. Not only are alternative materials and competitive processing routes significant elements of that challenge, but so are the globalisation of the automotive industry and progressive rationalisation of component supply chains.
Steel suppliers, forgers and other supply chain players must therefore co-operate effectively if engineering steel components are to meet the automotive industry's through-cost, weight, durability, recyclability and other performance expectations. This paper illustrates how, through working closely with its supply chain, involving forgers, machinists and end users, CES has exploited its materials expertise and the component design expertise of Corus colleagues, to develop innovative and effective solutions to the automotive industry's evolving needs.
|
|
| | Automotive steel forgings are under threat from alternative materials offering either reduced weight (e.g. aluminium) or reduced cost (e g. cast iron). The competition is particularly acute in the chassis, and it is not unusual to find a range of different materials and manufacturing technologies employed within modern suspension systems. British Steel Engineering Steels (BSES) has recognised that Early Vendor Involvement with vehicle manufacturers can be exploited in order to reverse the trend and promote the use of steel forgings. BSES has carried out two demonstration projects with a major vehicle manufacturer, involving two forging companies. One of the projects optimised an existing steel forging and the other successfully demonstrated the replacement of a cast iron component with a steel forging. The projects sought to optimise components in terms of design, manufacturing and materials, using the expertise of all elements of the supply chain and were coordinated by British Steel's Automotive Engineering Group (BS AEG). The results of the projects have shown that there is a significant opportunity to improve the weight and cost competitiveness of steel forgings and thus ensure their continued or extended use in future automotive applications. It has also demonstrated that the steel industry can present a highly credible automotive engineering input to vehicle programmes and become valued partners in those programmes at the earliest opportunity.
|
|
| | Distortion resulting from heat treatment has a significant effect upon final component costs. Most of the factors which influence distortion behaviour arise during the machining and heat treatment processes and are therefore outside the control of the steelmaker. One important factor which is under the jurisdiction of the steelmaker is hardenability. Consistent hardenability performance can have a significant effect in reducing the variability in distortion. In a number of instances, it has been shown that the macrostructure and as-cast shape of the steel can also influence distortion. Other downstream processing effects, such as forging, may also be influential in these circumstances. This paper gives examples of some of the experiences of British Steel Engineering Steels, with customers and endusers, and refers to relevant published work.
|
|
| | The market for air cooled steels has matured in the last 10 years. The advantages of these steels, in terms of elimination of heat treatment, reduced distortion, improved machinability and more consistent properties have led to their use in a wide range of automotive components.
In Europe, most forgers, working in partnership with steel producers, now have the necessary equipment and expertise to enable cooling after forging to be controlled accurately and reliably. The use of controlled rolling and cooling has also enabled the required mechanical properties to be achieved in bar stock without the need for heat treatment.
The paper reviews the grades of microalloyed and carbon manganese steels in current use and the properties of these steels. It considers how these properties can be influenced by the steelmaker through composition adjustment and controlled rolling, and by the forger by control of the forging and cooling conditions. A number of case studies are used to demonstrate these points.
Possible future developments of both microalloyed and carbon steels are also reviewed. These include the use of accelerated cooling and the use of higher carbon and nitrogen steels.
|
|
| | Over the next decade, the UK automotive supply industry faces great opportunities. This is particularly true of the forging sector, as part of that industry.
Nevertheless, steel forgers must also confront competition from a growing number of alternative material and processes. For the forgers to exploit the opportunities open to them necessitates not only their vigorous pursuit of process and product development, but also a recognition of the importance of supply chain partnership. This paper emphasises the equally important role of the steelmaker in that partnership.
|
|
| |
| |
| |
| | | |
