Development of new methods for determination of trimming die wear

该项目解决了当前阻碍福特工厂生产率和产品质量的问题， 在由高级高强度钢（AHSS）制成的汽车车身板上进行修整操作。 由AHSS钢制成的零件具有高强度质量比，因此对于汽车轻量化非常重要。 但是为了增加它们的使用，它们对切边模具造成的显著磨损损坏 应当减少。切边模具磨损具有不希望的后果，包括切边部件的性能恶化。 并且由于磨损的模具需要频繁更换而增加了操作成本。为缓解 模具磨损问题的第一步应该是开发一种测量方法，将确定模具寿命 准确和一致的方式。 拟议的工作包括开发一种方法，用于测量上，下修剪磨损 作为修边循环次数的函数，并考虑模具-工件间隙以及 模具角度。以前未应用于修边模测量的磨损测量方法 将在温莎大学材料摩擦学研究中心进行评估。这些将包括三个 由专用数字光学显微镜支持的三维非接触干涉测量方法， 大景深聚焦。无涂层和有涂层的DP 980型AHSS将在福特工厂进行修整， 将评估磨损的模具的损伤量以及表面损伤的类型， 包括磨损、材料转移磨损、塑性或微碎裂控制的损坏特征。的 研究将把磨损测量与可能发生在切削刃处的特定类型的磨损相关联， 结果将转交给福特。这些结果有望有助于福特的发展 确定模具磨损的标准。该项目将有助于提高修剪作业的效率 时间表和实施新的刀具磨损减少战略。

This project addresses a current problem that impedes productivity and product quality at Ford plants where trimming operations are performed on automotive body panels made of advanced high strength steel (AHSS). Parts made of AHSS steels provide high strength-to-mass ratio and thus are important for automotive light weighting strategy but in order to increase their use the significant wear damage they cause to the trim dies should be reduced. The trim die wear has undesirable consequences including deterioration of trimmed parts' edges and an increased cost of operation as the worn dies need to be replaced frequently. In order to alleviate the die wear problem the first step should be to develop a measurement method that will determine the die life accurately and in a consistent way. The proposed work consists of development of a methodology for wear measurements on upper and lower trim dies as a function of the number of trimming cycles-- and by considering the die-workpiece clearance as well as the die angle. Wear measurement methods that have not been previously applied to trimming die measurement will be assessed at University of Windsor's Tribology of Materials Research Centre. These will consist of three dimensional non- contact interferometry methods supported by specialized digital optical microscopes with large depth of field focus. Both uncoated and coated DP980 type AHSS will be trimmed at Ford's facilities and the worn dies will be evaluated for the amount of damage as well as the type of surface damage that may consist of galling, material transfer abrasion, plasticity or micro-chipping controlled damage features. The research will correlate wear measurements to the particular type of wear that may occur at the cutting edge and the results will be transferred to Ford. The results are expected to contribute to the development of a Ford Standard for determining die wear. The project will help to increase the efficiency of trimming operation schedules and implementation of new tool wear reduction strategies.