TLD TRENDS OF LASER APPLICATIONS IN HOTSTAMPING Michael Fritz, Industry Management Automotive 13.02.2014 TRENDS OF LASER APPLICATIONS, Michael Fritz 1 Commitments and Targets for CO2 reduction ACEA target was not achieved 2008 – EU Resolution 130 g CO2/km by 2012 95 g CO2/km by 2020 CO2 – Emission in g/km 200 150 100 50 0 1995 2000 TRENDS OF LASER APPLICATIONS, Michael Fritz 2008 2012 2015 2020 2025 Motivation to use Hotstamping About ¼ of the gas consumption is caused by weight TRENDS OF LASER APPLICATIONS, Michael Fritz Motivation for Hotforming Reduce fuel consumption -4.2 kg Increase safety TRENDS OF LASER APPLICATIONS, Michael Fritz 4 Process Chain Hotforming & Laser Applications Blanking Cutting blanks with laser Edge ablation TWB & Patchwork Ablation with TWB with TruMicro TruDisk TRENDS OF LASER APPLICATIONS, Michael Fritz Tool properties Laser Metal Deposition / LMD Laser cutting 3-D Cutting TruLaser Cell Partial Softening Softening with Laser marking induction or laser and welding Technology Trend: Tailored properties TASKS Further weight savings Solution Technology TWB of various ductility Combination of various thickness Improving crash worthiness TRUMPF Applications 1. AlSi ablation with TruMicro TWB of various thickness Softening of flanges 2. TWB with TruDisk Softening of areas (soft Band) Increase Energy absorption Tailored tempering in furnace Combination of various hardness Reduce risk of cracking / embrittlement TRENDS OF LASER APPLICATIONS, Michael Fritz 3. Softening with laser Tailored tempering in tool Tailor TailorRolled RolledBlanks Blanks 4. Softening with TruHeat Process Chain Hotforming & Laser Applications Blanking Cutting blanks with laser Edge ablation TWB & Patchwork Ablation with TWB with TruMicro TruDisk TRENDS OF LASER APPLICATIONS, Michael Fritz Tool properties Laser Metal Deposition / LMD Laser cutting 3-D Cutting TruLaser Cell Partial Softening Softening with Laser marking induction or laser and welding Trend: Tailored properties Tailor Welded blanks for different material thickness Tailor welded blanks for different material properties (e.g. hard top, ductile bottom) Challenge: AlSi coating and subsequently aluminum in the weld seam cause failure of weld Solution: Removal of the AlSi coating along the seam before welding thick thin Source: R. Vierstraete, „Laser ablation for hardening laser welded steel blanks,“ Industrial Laser Solutions, 26 01 2010 TRENDS OF LASER APPLICATIONS, Michael Fritz 8 Process requirements Removal of 10-25 µm AlSi along the welding edge of blank Adjustable remaining Al content (down to 0%) Preserve properties of base material Removal width of 1 mm – 2 mm Simultaneous removal of two sides of blank Linear removal speed of >30m/min TRENDS OF LASER APPLICATIONS, Michael Fritz 9 Optical arrangements: Fiber, Focusing and Laser round square rectangular line focus Ratio 1:10 TRENDS OF LASER APPLICATIONS, Michael Fritz Heat conduction in the ablation process Square Rectangle Line 1:1 1:2 1:10 25% 33% 45 % 25 % of heat conduction in direction of ablation 33 % of heat conduction in direction of ablation 45 % of heat conduction in direction of ablation + 32 % + 80 % TRENDS OF LASER APPLICATIONS, Michael Fritz Summary and facts of the process Thermal Process For good process quality and efficient process speed a high energy density and a laser with high pulse-frequency needed Ablation rate, quality, speed and residue of Al can be adjusted with optical setup and process parameters Process Speed >30m/min. TRENDS OF LASER APPLICATIONS, Michael Fritz 12 Process Chain Hotforming & Laser Applications Blanking Cutting blanks with laser Edge ablation TWB & Patchwork Ablation with TWB with TruMicro TruDisk TRENDS OF LASER APPLICATIONS, Michael Fritz Tool properties Laser Metal Deposition / LMD Laser cutting 3-D Cutting TruLaser Cell Partial Softening Softening with Laser marking induction or laser and welding Trend: Large and complex parts Complete door rings out of one part Body sides 1540 More laser cutting content due to complexity Longer cycle times Larger machine envelope 3540 Arbeitsbereich Y2000 mit Rotationswechsler TRENDS OF LASER APPLICATIONS, Michael Fritz 14 Trend: Pre-developed parts T>1,0mm = Prestamped Typically parts with low complexity of geometry T~0,5mm = Laser cut pre-cut contours shorter cycle times Pre-Developed TRENDS OF LASER APPLICATIONS, Michael Fritz 15 Machine Development TLC 1005 130 120 TruLaser Cell 7040 TruLaser Cell 8030 120 TLC1005, 3.2 kW 110 TruLaser Cell 7040, 5kW 100 Application development 90 82 80 76 70 Control optimization 73 Increased dynamics 69 57 60 50 FastLine Cell 52 47 40 Advanced laser power control TruDisk 30 20 10 0 2005 2006 – 2010 Performance package 7040 TRENDS OF LASER APPLICATIONS, Michael Fritz 2011 Example: B-pillar cutting length: 6305 mm Productivity improvements and technical trends Performance package Cutting time 140 Machine 120 Operator is bottle-neck of operation! Operator 100 Distribution of Cycle times 80 60 30-50 s >50 s 40 <30 s 20 0 2005 2006 2007 TRENDS OF LASER APPLICATIONS, Michael Fritz 2008 2009 2010 2011 2012 Year Loading strategies for TruLaser Cell 8030 Manual loading TRENDS OF LASER APPLICATIONS, Michael Fritz Automated loading cycle 18 Operating cost reduction: generation 2005 vs. 2011 TLC 1005 1,80 € 100% 1,60 € 90% 1,40 € 80% 1,2070% € TruLaser Cell 7040 1,0060% € 0,8050% € 40% 0,60 € 30% 0,40 € 20% 0,2010% € - € 02005 2005 TLC 1005 3,2 KW TRENDS OF LASER APPLICATIONS, Michael Fritz Produktionskosten Laser Pro Benchmark Bauteil with TruLaser Cutting Air Cutting Cell 7040 air instead 5 KW CO2 of nitrogen 2011 TruLaser Cell 8030 mit TruDisk TruLaser Cell 8030 *machine hourly rate including write-off, excluding operator 19 Process Chain Hotforming & Laser Applications Blanking Cutting blanks with laser Edge ablation TWB & Patchwork Ablation with TWB with TruMicro TruDisk TRENDS OF LASER APPLICATIONS, Michael Fritz Tool properties Laser Metal Deposition / LMD Laser cutting 3-D Cutting TruLaser Cell Partial Softening Softening with Laser marking induction or laser and welding Softening with Laser Softening Flap: allow the bending of small features without risk of fracture Softening hole perimeter: allow the bending of hole border to form a collet Softening Spot: soften are to allow to place a rivet Application boundaries: Material properties don‘t need to match exactly the base material before the hardening process Application can be handled directly after cutting the part in the Cell 8030 TRENDS OF LASER APPLICATIONS, Michael Fritz Softening with Laser or with Induction Partial softening of flanges Create ductile areas to reduce possibility of embrittlement for welding processes Material properties can be adjusted close to property of base material before the hardening Solution with laser or with Induction TRENDS OF LASER APPLICATIONS, Michael Fritz Movie TRENDS OF LASER APPLICATIONS, Michael Fritz Thank you for your attention! Michael Fritz Industry Management Automotive [email protected] TRENDS OF LASER APPLICATIONS, Michael Fritz
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