Engineering Research Center for Net Shape Manufacturing
Posted by: Administrator on Saturday, February 02, 2002 - 03:51 PM
Established in 1986, the Engineering Research Center for Net Shape Manufacturing focuses on the manufacture of discrete parts to net or near net dimensions via tube hydroforming, stamping, precision forging, and high-performance machining. The ERC/NSM is the leading R&D group in Tube Hydroforming technology in North America. The Tube Hydroforming (THF) consortium is conducted with the support of the National Science Foundation and more than 30 companies worldwide.
Aida Engineering, Ltd., JAPAN
Alcoa, PA, USA
Benteler Industries, Inc., MI, USA
Bethlehem Steel Corp., PA, USA
Budd Co., MI, USA
Cardington Yutaka Technologies, OH, USA </li
li>Cockerill Sambre, BELGIUM
Daimler Chrysler, GERMANY
Dana Corp., PA, USA
Erie Press Systems (EPS), PA, USA
Extrude Hone Co., PA, USA
Honda R&D Americas, Inc., OH, USA
Hydro Raufoss Automotive, MI, USA
Johnson Controls, WI, USA
Kawasaki Hydromechanics Corp., JAPAN
Kawasaki Steel Corp., JAPAN
Kobe Steel Ltd., JAPAN
LTV Steel Tubular Products Inc., OH, USA
MascoTech Tubular Products Division, MI, USA
Mold Tooling Systems (MTS), MI, USA
Nippon Steel Corp., JAPAN
POSCO Technology Management Dept., KOREA
Reynolds Metals, VA, USA
Schuler Hydroforming GmbH & Co, GERMANY
Siempelkamp Pressen Systems (SPS) GmbH, GERMANY
Tenneco Automotive, MI, USA
Tower Automotive, WI, USA
Vehma International of America, Inc., MI, USA
Weirton Steel Corp., WV, USA
The ultimate goal of the THF consortium is to develop computerized guidelines for designing tube hydroforming part, tooling, and process for given part geometry and material properties. To fulfill the goal, five main research tasks are carried out.
Formability tests of tubular materials
Pre-forming and bending tube analysis
Function and lubrication
Finite element analysis based die and process design
dvelopment of guidelines for part and process design for Tube Hydroforming
Maximum Thinning is 37%
Automotive Structural Part Simulation - good agreement between FEM predictions and experimental data ( experimental part provided by Dana Corp., 1998)
Bulge tests at a tube manufacturing company
Forming of Y-shapes at the facilities of a press builder
Bulge forming of various sections at the facilities of a die manufacturer and press builders
Forming of structural parts with inserted tooling, in cooperation with a press builder
At the ERC/NSM, we designed and developed the formability test tooling which is used to generate mechanical property data for tubular materials commonly used in tube hydroforming industry. We also have a custom viscous media tube forming tooling and a custom tube forming friction test tooling which can be used to conduct experiments on our Minster Double Action 160 ton Hydraulic press. As for the computation facilities, the ERC/NSM is using commercial software, which is widely used by industry, such as PAMSTAMP, LS-DYNA 3D, DEFORM and FEMB for FEM process simulation purposes; I-DEAS and Pro/Engineer for CAD design purposes.
In addition to the experiments conducted at the ERC/NSM, a series of experiments are planned to be conducted at the facilities of the member companies as they offer advantages of running experiments in the real industrial tube hydroforming production systems.
SS 304 Tubes used in Formability tests
The ERC/NSM usually held conferences about hydroforming.
Please visit the ERC/NSM web site at http://nsmwww.eng.ohio-state.edu/ for more information or check the schedule web site at hydroforming.net.
THE OHIO STATE UNIVERSITY, OHIO, USA.
phone: +1 (614) 292-9267
fax: +1 (614) 292-7219
Published with the permission of the ERC/NSM of The Ohio State University