Transcript ECOLE DES MINES D'ALBI

CR
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ECOLE DES MINES D ’ALBI
RESEARCH CENTRE
ON TOOLS, MATERIALS AND
PROCESSES
CROMeP
CROMeP_2000_eng _LP_I
6-00
CR
MeP
FRENCH ECOLE DES MINES NETWORK
BELGIUM
• Bruxelles
• Frankfort
PARIS
Financed and run directly
by Ministery of Industry
GERMANY
Douai •
7 schools
Nancy
Nantes
SWITZERLAND
• Geneva
• Lyon
• Saint Etienne
• Bordeaux
Albi
Toulouse •
SPAIN
Barcelone •
• Alès
• Montpellier
ITALY
Milano •
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Centre de Recherche sur les
Outillages, les Matériaux et les
Procédés
Research Center on Tools, Materials and Processes
Founded in 1993
Industrial oriented research
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global approach for tooling and processes problems
Research on tool materials used in
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forging, casting, hot rolling, sheet metal forming, superplastic
forming, injection molding, glass industry, etc
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WHY THIS THEME ?
Significant ecomical impact in material industry
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direct : raw materials, machining, treatment
indirect : cost saving, product quality, productivity
R &D in a industrial company
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Partially activity
Tool manufacturing is often subcontracted
Diversification of professions
Multidisciplinary problems
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In 12/17/99 : 45 persons
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18 scientists & engineers
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5 technicians
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2 secretaries
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19 Ph.D. students
2 Post-Doc
TEAM
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Microstructure &
Damage
Characterization
Material Testing
Tool coating testing
PLURIDISCIPLINARY
APPROACH
Material Processes
- metals
- polymers
- glasses - ceramics
- composites - ...
Thermal & Mechanical
analysis of tools
- undersdanding
- optimisation
- prevision
Physical characterization
of materials
Non destructive
testing
Process & flow
simulation
Thermo-mechanical analysis
of molds, dies and tools (FE).
Mold, dies & tools testing
on pilot plants
Computer vision applied
to process control
Surface treatment,
coating & lubrification
Thermal monitoring of industrial
equipments; Infra Red
Thermography
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4 SCIENTIFIC RESEARCH AXIS
Measurement of tool sollicitations
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Heat flux, temperatures and displacements
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Contact less measurement technics (CCD cameras, infra-red)
Behaviour and reliability of tool materials
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Material behaviour and modeling
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Isothermal and non-isothermal
Surfaces
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Performance reliability of tools surfaces
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Thermomechanical fatigue life, wear and damage
Modeling and design of tools
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Coupled or un-coupled mechanical, thermal and chemical modelling
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Mechanical
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isothermal fatigue (1200°C)
non-isothermal fatigue (induction)
mechanical & optical extensometry
High temp. flexural on ceramics
micro- hardness (RT and HT)
high temperature Charpy
Thermal expansion
TEST FACILITIES
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Portable monitoring equipments
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Pilot plants
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Microstructural analysis
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metallographic examination
image analysis
S.E.M.with EDXS& EBSP (local
crystaline orientation)
X ray surface residual stress
measurement
3D nano roughness (with & without
contact)
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infra red cameras (3-5µm & 8-12µm)
thermocouple acquisition system
image acquisition (C.C.D.)
thermoplastic injection
Aluminium casting equipment
Wear in sheet metal forming
Thermal treatment
Software
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process simulation
• forging,rolling,forming : FORGE 2
• stamping : PAM-STAMP
• casting : Thercast
• Plastic injection : IDEAS
• thermal & surface treatment : SYSTUS
• thermomechanical analysis : ABAQUS, SYSTUS
• CAD : IDEAS, AUTOCAD
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RESEARCH CONTRACT
ORIGINS
Industrial contracts
•Regional
•National
•European Community
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MANPOWER RESOURCES AND
RESULTS
PhD student
Tech
Prof. & Ass.Prof.
Staff
50
50
40
40
30
30
20
20
10
10
0
0
1995
1996
1997
1998
1999
Research turnover (Million of FF)
4
3,5
3
2,5
2
1,5
1
0,5
0
1993
1994
1995
2
1,1
1996
1997
1998
1998
1999
5
5
4
3
2
1
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3,3
1995
1996 1997
PhD graduates
3,7
1,9
Others
Conf. with proceed.
Publications
Research papers
1999
0
0
1995
1996
1997
3
3
1998
1999
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RESEARCH APPROACH
Two basic orientations
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A-Laboratory scale : Materials characterization and
assessment
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B-Pilot scale : Reproduce and simulate phenomena
to reach scientific unterstanding and develop the behaviour and
life prediction models
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MATERIALS CHARACTERIZATION
1-Identification of the initial state of material and their
development
 Mechanical properties & behaviour laws measurements
 Cracks, thermal & mechanical damage identification
 Assessment of the process induced sollicitations
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Development of interactions between processes and tools
2-Monitoring & identification of industrial equipment
operating parameters with mobile equipments
 Stereovision rigs
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Mechanical properties & behaviour
laws measurements
Carbide micro-crack after
monotonic load at 500°C
Choi, Baleix, Bernhart, Lours
Thermomecanical stress
during fatigue test at
500°C and 900°C
Superplatic forming
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Cracks, thermal & mechanical
damage identification
Uniaxial and biaxial crack
during thermal fatigue
Jean, Oudin, Miquel, Rezai-Aria
Temperature effect on the
thermomechanical life
Forging
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Numerical simulation of
forging operation
with FORGE2
Oudin, Penazzi, Rezai-Aria
Assessment of the process
induced sollicitations
Fatigue life calculated
Critical area
prediction and
time life
Forging
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Cracks in casting mold
Mold : cast-iron
Baroucaire, Michrafy, Dour
Development of interconnections
beetween process & tool
Thermo-elastic stress during
aluminum casting
mold : 240°C - Al : 750°C
Casting
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Monitoring & identification parameters
with stereovision rigs
3D shape measurement with
stereocorrelation method
Garcia, Orteu, Rezai-Aria
2D crack propagation an dfrfacture
thougnhess measurement
during 3 points bending test
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Microstructure and behavior of
reinforced concretes
Dilation evolution of
refractory concrete
reinforced by metallic fibers
Cailleux, Cutard, Bernhart
Prototype insert moulds
Superplastic forming
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Infrared heating of
thermoplastic preform
Temperature contours of
preform and lighters during
heating
Monteix, Le Maoult, Schmidt
Modeling of preform
heating
Thermoplastic heating
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REPRODUCE & SIMULATE
PHENOMENA
With classical or special designed test equipments
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Thermal and mechanical test equipments
Tribology and wear test facilities
With instrumented industrial or pilot equipments
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Sheet metal forming tools wear resistance
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Plastic injection facilities
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Heat treatment and quenching facility
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Thermal and mechanical test
equipments
Thermomecanical fatigue machine
Thermal fatigue rig
Material behaviour laboratory
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HT Tribometer equipement
Tribology and wear test
facilities
Friction coefficient variation with
sliding length for 35NCD16 steel
Without oxydation
Pre-oxydation 400°C
Pre-oxydation 750°C
Time (s)
Boher, Vergne
Tribology laboratory
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Sheet metal forming pilot
Sheet metal forming tools wear
resistance
Tools geometries
Strain gages
and thermocouples
instrumented tools
3-axials force cell
5 KN - 150 mm/s - continuous or 10 cycles/min - coil : 200 kg
Boher, Lamesle, Penazzi
Technical Hall
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Injection facilities
Injection moulding machine with modular molds
Wesselman, Saint-Martin, Devos
Technical Hall
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Heat treatment
vacuum furnace quenching
Heat treatment & quench facility
Shape variations monitoring
for Austenitic Stainless Steel
X2CrNi18-9 during cooling
End 135s
225s
110s
Claudinon Lamesle, Orteu
55s
50s
25 s
Thermal and surface traitement laboratory
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International Network on Forming
Tools Research and Development
Aim
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To promote exchanges between research groups involved in
Forming Tools (from academic institutions and technical centers)
To prepare common response to international calls for proposal
(like EEC programs)
To reinforce lobbying inside national and international committees
to promote research and education of engineering students on
forming tools
To organize conferences, workshops and short courses on the
forming tools domain
To develop data base and information collection on forming and
molding tools
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forging,
superplastic forming
sheet metal forming
casting,
injection moulding,
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International Network on Forming
Tools Research and Development
Call for partnership to join the International
Network on Forming Tools Research and
Development
Please contact :
Prof. C .LEVAILLANT
Head of CROMeP Research Centre
Ecole des Mines d ’Albi
F-81013 ALBI cedex 09 - France
Phone : +33 563 49 30 79 - Fax : +33 563 49 32 42
email : [email protected]
http://www.enstimac.fr/
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International Network on Forming
Tools Research and Development
Cases of sheet metal forming tools
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75 references papers from 1997 to 1999
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Main country :
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S
4%
NL
7%
France, Germany, USA, etc
J
6%
Main actors :
 Aalborg Univ., Hanovre Univ.,
 MIT, Ohio State Univ., TNO, etc
Main topics :
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Friction, design, material, tool
technology, etc
F
26%
KO
3%
G
19%
UK
6%
economic
5%w ear
manufact.
2%
control BH
2%
2%
DK
7%
USA
10%
friction
24%
8%
coating.
8%
design
15%
computer
simulat.
10%
tool
technol.
11%
material
13%
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EXCHANGE OFFERS
Post-doc students
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mechanical and materials sciences
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work proposed :
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sheet metal forming tools (material, coating, wear)
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tribology at high temperature
Visiting professors
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mechanical and material sciences
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at least 6 months