Product category:
Press tools - design, manufacture and usage, CAD/CAM, software
News Release from: Corus Automotive | Subject: Portable strain measurement system
Edited by the Manufacturingtalk Editorial
Team on 28 March 2008
Portable strain measurement optimises
press tools
A portable strain measurement system has helped optimise press shop tooling, which has facilitated the introduction of new steel on a current production vehicle.
Corus has used its knowledge in the use of a portable strain measurement system to help Ford optimise its press shop tooling at the company's Genk plant in Belgium, which has facilitated the introduction of new steel on a current production vehicle Corus Strip Products IJmuidens, The Netherlands, delivers some 70,000 tonnes of steel/year to the Ford Genk plant in Belgium
This article was originally published on Manufacturingtalk on 31 May 2006 at 8.00am (UK)
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Corus engineers from the company's Research Development and Technology Centre in IJmuiden, have assisted Ford Genk in using a portable strain measurement system to help them better understand how steel performs during sheet metalwork pressing.
Corus developed the knowledge of on-site strain measurements to help carmakers ensure reliable production quality of complex formed body panels during vehicle development and production processes.
* Advanced high strength steels - the use of strain measurement technology by carmakers is increasingly important as more OEM's turn to the latest generation of advanced high strength steels.
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By measuring strain measurements on site at Genk, Ford engineers were able to introduce a new steel for selected parts on a current production vehicle after testing to ensure that the new material would be able to perform consistently on the existing press tool die line-up.
Corus was the first company to bring to market a system, called PHAST , that combined expertise in 3D measurement technology with materials knowledge.
The knowledge gained over the last few years by using this system has now given Corus the capability to offer vehicle manufacturers a complete package to enable them to optimally process today's modern automotive steels with increased confidence.
* Photography - using a strain measurement system involves photographing a test-prepared panel from different positions using a digital camera.
The software then links all the photographic measurements automatically, calculating the strains in the pressed part to an accuracy of +/-0.5 per cent strain.
The results are typically available within 1h.
Results are used to make often small changes to the press tool geometry, which means subsequent problems in volume production are avoided and panel quality is improved.
At Ford Genk, more than 40 grids were used to measure strain levels on 15 blanks for the Corus and a competitor's steel products.
In all, Corus engineers tested six major parts on site, including the following.
* Two tailgate outer panels.
* One tailgate inner reinforcement.
* A bodyside outer.
* Two other bodyside reinforcement panels.
At the end of the trial, intermediate results were presented to the Ford Genk press shop management.
It was successfully demonstrated that the Corus material could be pressed without changing the settings on their power presses.
The proving process demonstrated a reliable stamping process, and thus safer stamped products.
Corus Strip Products IJmuiden support engineer, Marcel Borst, said to manufacturingtalk: "One of the key benefits of our strain measurement system is that it is easily portable and can be used on-site with the customer.
The work at Ford Genk is a good example of this" He added: "The cooperation between Ford Genk and Corus again demonstrates the major benefits available to carmakers from Corus providing critical on-site body shop support that helps optimise material usage and performance".
Corus has has successfully deployed on-site strain measurements with other automotive customers including working on-site at NedCar's assembly plant in Born, the Netherlands, to help optimise final press tooling for the manufacture of the Mitsubishi Colt. Request a free brochure from Corus Automotive ...
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