Advanced forming and manufacturing technology for automotive panels above 980MPa

Hegang Group has established a comprehensive technology research and development platform with 3 national recognized enterprise technology centers, 6 provincial-level recognized enterprise technology centers, 7 CNAS recognized physical and chemical laboratories, as well as 6 provincial-level engineering technology research centers for cold rolled and coated steel plates, steel structural steel, etc. It also has 3 academician workstations and 3 postdoctoral research workstations. We have equipped over 10 sets of first-class simulation pilot equipment for steel rolling and deep processing, as well as over 130 high-end physical and chemical testing equipment for physics, chemistry, and mechanics. We have built a simulation platform and established a user forming laboratory with simulation software such as CatiaV5, Dynaform, Ansys, Abaqus, and Adina. We have established the Hegang UQ Sustainable Steel Innovation Center with the University of Queensland, and have initiated a project titled "Application of New Technologies for Deep Processing of High Strength Automotive Steel" with a supporting funding of 3 million yuan. We plan to apply for a special funding of 500000 yuan for talent introduction. The breakdown of the expenses is as follows: international travel expenses, petty expenses (or salary subsidies), accommodation expenses, inter city transportation expenses, technical guidance fees, teaching fees, patent technology transfer fees, translation fees, totaling 1010551082050. The partner, Australia, has 6 participants, and Hegang Group has 12 participants. The information of the proposed expert is as follows: resume of the proposed expert's work, education background, 1980-1984, Department of Mechanical Engineering, Tianjin University of Light Industry, Bachelor of Engineering 1997 – 1998 Department of Mechanical Engineering II, Northeastern University, Master of Mechanics 1997 – 1998 Department of Mechanical Engineering, University of Auckland, New Zealand, Master of Mechanical Engineering 1998 – 2000 Department of Mechanical Engineering, University of Auckland, New Zealand, Doctor of Mechanical Engineering. Work experience 1984 – 1987, Department of chemical engineering, Zhengzhou Institute of Light Industry, Assistant, 1990-1995, Department of Mechanical Engineering, Northeast University, Lecturer, 1995-1997, Auckland UniServices, New Zealand, R&D Engineer, 2000 – 2001, BHP Steel Mill Research Institute, Australia, Mechanical Engineer, 2001 – 2003, Department of Mechanical Engineering, University of Auckland, New Zealand, Lecturer, 2005 – 2010, Department of Mechanical Engineering, University of Queensland, Australia, Researcher 2010-2013, Department of Mechanical Engineering, University of Wollonggang, Australia. Lecturer and doctoral supervisor, Department of Mechanical Engineering, University of Queensland, Australia, 2014-present. Lecturer and doctoral supervisor. Ding Shichao is an expert in the field of sheet metal forming and an inventor of multiple sheet metal forming technologies. Hundred foot molding and chain molding are representative achievements. He has over 30 years of experience and experience in teaching, scientific research, industrial research and development, and market applications. His research projects are highly innovative and have received high support from industrial partners such as Smorgon Steel Plant in Australia, Baosteel, River Steel, and automotive manufacturers. He first proposed the concept of optimizing transition surfaces through cold bending forming and put it into practice, and based on this, he successively invented two efficient forming technologies: hundred foot forming and chain mold forming. Its technical feature is to greatly reduce or even eliminate excess strain during the cold bending forming process, eliminate the root cause of product defects from the mechanism, reduce residual stress in the product, and greatly reduce the required energy consumption. Baizu forming and chain mold forming are gradually being accepted and applied by the industry, especially in the field of high-strength steel. Dr. Ding has completed and is currently undertaking multiple research projects. Among them, ARCLinkage in Australia (2007, $210000 Australian dollars, Queensland University), Unique project (2010, $800000 Australian dollars, Queensland University transferred $450000 Australian dollars to Wulonggang University), Baoao project BA13014 (2014, $350000 Australian dollars, Queensland University), ongoing projects include the River Steel project (2017, ICSS17-01, $500000 Australian dollars for 3 years) and Baoao project (2018, BA17013, $200000 Australian dollars), Dr. Ding also invented a residual stress measurement method for sheet metal forming products, which has attracted the attention of scholars from the Australian Institute of Nuclear Physics (ANSTO) and the University of Tokyo in Japan. So far, Dr. Ding has guided and trained 2 doctoral students, 1 master's degree student, and 2 current doctoral students. Published over 10 articles in international journals and at international conferences, with 5 international patents and 3 Chinese patents. The technical difficulties of this project lie in the following aspects: (1) The implementation of integrated stability control technology for processes and equipment requires the configuration of equipment such as leveling machines, precision machines, welding machines, and cutting machines. Failure to achieve continuous stable production processes and equipment control technology poses risks. In the future, simulation of the entire production process and equipment parameters will be carried out to optimize the structure and parameters of the production line equipment, ensuring the stability of the process and equipment technology. (2) If the mold design is not reasonable and the forming process optimization is not in place during the forming process of ultra-high strength steel, defects such as product forming cracking and edge waves may occur. (3) Ultra high strength steel automotive components are green products, and their use in the new energy vehicle industry is also in line with the country's medium to long-term development strategy, and the policy risk is also very small. (4) The constraints in the implementation process are reflected in the need for Hegang Group to coordinate the management, technical exchange, and resource allocation of various platforms for internal and external cooperation, which may affect the overall project schedule. However, Hegang Group has rich experience in managing similar projects, which can ensure the smooth implementation of projects. The solution to technical difficulties first involves organizing production and sampling of the steel coils described in the parts at various subsidiary companies of Hegang Group, and testing the mechanical and tensile properties of the steel coils to establish a simulation database. Then, based on the part specifications, performance requirements, and database, simulation software is used to design and optimize the overall production process, specific forming process, and mold cross-sectional dimensions of the part. According to the design requirements, the mold blocks are produced and processed, and all equipment required for the production line is selected and configured. At the same time, a combination of simulation and experimentation is used to research and develop the corresponding equipment and its application technology, and then the production line equipment is debugged and finalized. After the equipment debugging is completed, product technology research is carried out to optimize production process parameters based on product size accuracy and performance requirements, and then authoritative certification, testing, and evaluation are conducted on the final product. Research on Technical Difficulties: This project adopts a new type of cold bending forming technology to carry out technical research on the forming process, production equipment and application, product quality evaluation, and other aspects of high-strength/ultra-high-strength steel automotive parts. This includes the following aspects: (1) Design and optimization of the new cold bending forming process; (1) Establish a material database required for simulation and simulation. Including basic mechanical properties such as elastic modulus, strength, elongation, as well as the mixed hardening model (Chaboche model) obtained by fitting experimental data such as tension and compression tests and pure bending. 2) Based on part specifications and quality requirements, material performance databases, simulation technology is used to design and optimize the overall production process and forming process of the parts. Reasonably allocate the forming amount of each pass to obtain the forming knurling diagram. 3) Preliminary design of the mold is carried out based on the forming knurling diagram, and the rebound value of the material is studied through simulation and experimental methods. The final optimization design of the mold section size is carried out. (2) Design and optimization of production line equipment 1) Production and machining of mold steel. Machine the designed molds to obtain qualified mold blocks with dimensions and surface hardness. 2) Design the production line process based on the overall production and forming process of the designed parts, and select and configure important equipment on the production line based on data such as rolling force, torque, and tension. 3) Optimize the equipment parameters of the production line through simulation and experimentation. Optimize the parameters such as under pressure, rolling force, unit spacing, downhill amount, tension, etc. of the cold stand based on product size and performance requirements. 4) Debugging and operation of the unit. 3. Production and manufacturing technology and product performance evaluation of high-strength components for new energy vehicles. 1) Research the impact of production process parameters on product dimensional accuracy and application performance, forming a production process technology with high dimensional accuracy and usage performance requirements. 2) Authoritative certification, testing, and evaluation of the dimensional accuracy and usage performance of various products produced. For example, conducting performance tests on automotive components such as fatigue, durability, and crushing. The expected goals to be achieved are as follows: (1) After applying the new material database model and the mixed hardening material model, the simulation accuracy will be improved by more than 10%. (2) For the same type of high-strength steel automotive steel products, the new cold bending forming production line will reduce production passes by more than 38% compared to traditional production lines, And can form high-strength steel above 1500MPa. (3) The dimensional accuracy of the product reaches ± 0.75mm. (4) The residual stress in the non plastic deformation zone of the product is less than 100MPa. (5) The production line speed reaches 10m/min, and the product qualification rate reaches 92% or more. (6) Completed 2-5 related papers and applied for 2-4 invention patents. With the decrease of strength, the formability of ultra-high strength steel decreases. When the tensile strength exceeds 1500MPa, the elongation is generally less than 5%. It is difficult to effectively control rebound and forming fracture when using cold stamping. With the rapid development of China's automotive industry, pressure from environmental protection, safety, and human comfort needs is increasing, and there is an urgent need to improve energy efficiency, safety, and reduce production costs. A large amount of data shows that the application of advanced high-strength steel above 980MPa can achieve a vehicle weight reduction of 12% -20%, reduce traditional vehicle fuel consumption by 6% -8%, improve safety performance, reduce new energy vehicle manufacturing costs, and increase driving mileage by 5.5%. Compared to materials such as aluminum, magnesium, and carbon fiber, ultra high strength steel above 980MPa has the lowest cost and is the most commercially valuable lightweight material. At present, Hegang has successfully developed products such as DP, MS, QP steel with a pressure of over 980MPa, and further development of forming application technology is needed. With the decrease of strength, the formability of ultra-high strength steel decreases. When the tensile strength exceeds 1500MPa, the elongation is generally less than 5%. When using cold stamping, it is difficult to effectively control rebound and forming fracture. When using hot stamping, the surface quality of the steel plate is poor, the production cost is high, and the material yield is low when using roller forming. There are quality problems such as port blooming, edge waves, and twisting. In fact, the development of ultra-high strength steel forming technology is a global challenge. China, Japan, Germany, South Korea and other countries are competing to develop new forming technologies such as flexible roll forming and hot roll bending, but the technology is still immature and cannot be applied to the automotive industry. This project innovates the most advanced progressive forming and optimal surface design ideas in the world, solving the problems of excessive deformation and energy consumption in non deformation areas during the forming process. It can reduce manufacturing costs by 10%, improve the yield of advanced high-strength steel parts, reduce residual stress in non deformation areas, improve the forming and manufacturing accuracy of ultra-high strength automotive steel parts, and greatly improve the safety of applying ultra-high strength steel. After the implementation of this project, it can be promoted and applied in the manufacturing of high-strength automotive panel parts for new energy vehicles. It is expected to promote over 1 million tons of advanced steel materials annually, creating economic benefits of over 1 billion yuan. At the same time, advanced steel materials have been applied to new energy vehicles, achieving a lightweight effect of over 20%, significantly increasing range, improving energy efficiency, reducing greenhouse gas emissions, significantly reducing production costs, and creating huge social benefits.