Research Papers

Determination of the Active Medium Temperature in Media Based Press Hardening Processes

[+] Author and Article Information
Welf-Guntram Drossel

Fraunhofer Institute for Machine Tools
and Forming Technology IWU,
Reichenhainer Strasse 88,
Chemnitz 09126, Germany
e-mail: welf-guntram.drossel@iwu.fraunhofer.de

Norbert Pierschel

Technische Universität Chemnitz,
Professorship for Machine Tools
and Forming Technologies,
Strasse der Nationen 62,
Chemnitz 09107, Germany
e-mail: norbert.pierschel@mb.tu-chemnitz.de

Alexander Paul

Fraunhofer Institute for Machine Tools
and Forming Technology IWU,
Reichenhainer Strasse 88,
Chemnitz 09126, Germany
e-mail: alexander.paul@iwu.fraunhofer.de

Klaus Katzfuß

Hochdruck- und Sonderhydraulik Leipzig GmbH,
Edisonstrasse 12,
Schkeuditz 04435, Germany
e-mail: hslmail@online.de

Rico Demuth

Fraunhofer Institute for Machine Tools
and Forming Technology IWU,
Reichenhainer Strasse 88,
Chemnitz 09126, Germany
e-mail: rico.demuth@iwu.fraunhofer.de

1Corresponding author.

Manuscript received February 26, 2013; final manuscript received October 23, 2013; published online February 5, 2014. Assoc. Editor: Gracious Ngaile.

J. Manuf. Sci. Eng 136(2), 021013 (Feb 05, 2014) (8 pages) Paper No: MANU-13-1075; doi: 10.1115/1.4025812 History: Received February 26, 2013; Revised October 23, 2013

Safety, lightweight design, and reduction of emissions are terms which are key issues in modern vehicle construction. These challenges can be met by new lightweight design strategies, e.g., by using lightweight materials and high-strength steels as well as innovative forming technologies such as media based press hardening (MBPH). MBPH as a sub-production technique of hydroforming is a tempered internal high-pressure forming process of closed profiles, which this article is about, or sheet metals by gaseous media. Due to the high process requirements (internal pressure up to 70 MPa and temperatures up to 1000 °C), it has not been possible to measure the temperature curve of the active medium in a reliable way until now. The aim of the research project described in this article was to develop an innovative measuring instrument to determine the gas temperature curve with a measuring frequency of at least 1 Hz. Analytical and numerical calculations have indicated that the active medium has a significant influence on the thermodynamic of the forming process. The finite element analysis (FEA) of the heat flow during the forming process has indicated that the influence of the gas on the cooling process of the work piece is about 15% of the total influence of the tool. Consequently, the active medium in media based press hardening processes is an important thermal influencing factor. Experiments have confirmed that it is possible to determine the calculated curve of the gas temperature and maximum temperatures of the active media up to 500 °C. The findings of these studies make a significant contribution to identifying and analyzing the complete temperature balance in tempered active media based forming processes.

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Fig. 1

Process diagram for media based press hardening

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Fig. 2

Cross-section illustration of the radiation shield device according to Ref. [7]

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Fig. 3

Geometric dimensions of the demonstrator

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Fig. 4

Illustration of the flow of active medium in the component part at t = 6 s and pi = 70 MPa

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Fig. 5

Change in the heat transfer coefficient and the heat flux density between the tool and work piece or active medium and work piece

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Fig. 6

Structure of the measuring system

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Fig. 7

Cross-section illustration of the radiation shield bush

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Fig. 8

Profile of the active medium temperature for tU = 9 s, tK = 3 s, material MW1000L, TWZ = 20 °C, TWS = 20 °C, pi,max = 70 MPa

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Fig. 9

Profile of the active medium temperature for tU = 6 s and tU = 9 s, tK = 3 s, material 34MnB5, TWZ = 100 °C, pi,max = 70 MPa

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Fig. 10

Profile of the active medium temperature if component parts fail at 60 MPa

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Fig. 11

Profile of the active medium temperature at tool temperatures of TWZ = 20 °C, 100 °C, 200 °C, 300 °C

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Fig. 12

Profiles of the active medium temperature for three work pieces, tU = 6 s, tK = 3 s, material 34MnB5, TWZ = 300 °C, pi,max = 70 MPa

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Fig. 13

Comparison of the simulated temperature profile and measured active medium temperature at 150 °C tool temperature




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