PRB. Development of a New Bending Method PRB for High Strength Steel Tube and Application of High Strength Steel Tubes for Automotive Parts

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1 JFE No p PRB Development of a New Bending Method PRB for High Strength Steel Tube and Application of High Strength Steel Tubes for Automotive Parts SUZUKI Koji TOYODA Shunsuke SATO Akio UENO Yukikazu OKADA Masao JFE JFE JFE JFE PRB 780 MPa 780 MPa Abstract: JFE Steel has developed a new bending method (PRB) for thin-walled high strength steel tubes without a mandrel and a wiper in collaboration with Toyota Motor Corp. and Taiyo Corp. JFE Steel also developed the 780 MPa class electric-resistance-welded tubes (ERW tubes) for automotive suspension parts, and contributed to the realization of the development of the arm parts applying 780 MPa class ERW tubes. By eliminating the mandrel and the wiper, which wear out eventually and require long adjusting time, in the rotary draw bender, this new bending method enables the bending of the thin-walled high strength steel tube in high productivity as well as enabling the bending of the thin-walled high strength steel tube with irregular shape THF THF 590 MPa 3 R 4 PRB Bending Method with Slight Reduction of Diameter by Push with Pressure Die and Rotation of Bending Die 52

R R/D R D 2.0 R 2. R 2.1 2.1.1 Fig. 1 R 1940 5 1950 6 1960 7 1980 CNC 8 Photo 1 R t/d 4 390 MPa R/D 4.5 R/D 1 R 9 390 MPa R CNC Cramping Fig.

2 R R/D R D 2.0 R 2. R Fig. 1 R CNC 8 Photo 1 R t/d MPa R/D 4.5 R/D 1 R MPa R CNC Cramping Fig. 1 Tube Mandrel Pressure Bending Wiper Booster Cylinder Schematic diagram of rotary draw bending (a) 2 Ball type mandrel (b) Wiper Photo 1 Tools for rotary draw bending Changing ratio of thickness (%) Fig Inside of bend Clemp Outside of bend Distance Bending angle ( ) Distance Wall thickness distribution of high tensile steel tubes in rotary draw bending (TS780 MPa electric resistance welded steel pipe, OD70 WT2.6 mm, R/D 2.05) R MPa 4 Fig R R R/ Fig Frantz JFE No

compression bending qtube, wspherical bearing,

4 w e r Schematic diagram of push through bendig 3.

6 PRB Bending Inroad of bending into the pipe Pipe

3 Fixed bending Tube 3. PRB Fig. 3 Clamp q Rotary pressure Schematic diagram of compression bending qtube, wspherical bearing, ebending, rguide cylinder Fig. 4 w e r Schematic diagram of push through bendig 3.1 PRB PRB MOS Fig φ114.3 mm CNC R R/D 2.0 R Fig T/D 5 10 R/D R PRB Fig. 6 PRB Bending Inroad of bending into the pipe Pipe Pressure Pressing before bennding Slight reduction in diameter Fig. 5 Schematic diagram of bend-rolling process Fig. 6 Principle of PRB method JFE No

8 70.0 mm 2.6 mm 780 MPa JIS 12A YS 757 MPa TS 803 MPa EL 17 R140 mm R/D 2.0 90 Changing ratio of thickness (%) Fig.

4 Tube Bending Cramping Pressure Wrinkles No wrinkles Fig. 7 Cylinder Cylinder Schematic diagram of PRB method Photo 2 Appearance of bent tube by rotary draw bending and PRB method PRB PRB Fig. 7 Fig PRB Photo 2 Fig mm 2.6 mm 780 MPa JIS 12A YS 757 MPa TS 803 MPa EL 17 R140 mm R/D Changing ratio of thickness (%) Fig Inside of bend PRB method 20 Rotary draw bend Outside of bend Distance Bending angle ( ) Distance Longitudinal thickness distribution of bent tube 2 Photo 2 PRB PRB Fig. 8 Photo 2 PRB PRB 45 PRB PRB 780 MPa Table 1 90 R/D 2.0 PRB 55 JFE No

5 Table 1 Spring back angle of bent tube by PRB method and rotary draw bending Grade: 780 MPa class Applied tube Size: OD70 WT2.6 mm Bending angle ( ) Bending radius of central axis Mandrel and wiper Pressure force by booster Pressure force by pressure Ellipticity (%) PRB method Rotary draw bending 10 None None 15 tf (147 kn) Cross section shape 3 ball-mandrel and wiper 10 tf (98 kn) None PRB PRB R 1 1 R Fig. 9 ξ 1 ξ H W OD Distance Fig. 9 Bending angle ( ) Ellipticity of bent tube Distance ξ (H W)/OD 1 4. PRB MPa 780 MPa R/D PRB 3 7 THF Fig. 10 Fatigue endurance Toughness Tube formability Low C ( 0.2) Low alloy (Si 1.0) Homogeneous microstructure (Ferrite Bainite) Property constancy Paintability Concept of material design about 780 MPa class electric resistance welded tube JFE No

Table 2 Merits by applying 780 MPa class ERW tube to automotive part bent by PRB method Items Press formed part (Steel sheet) Bent and hydraulic formed part (ERW tube) Total number of production

class ERW tube Si Fig. 10 1 2 3 22 PRB Photo 3 780 MPa 4.2 17 4.2.1 780 MPa 780 MPa PRB φ70 t 2.6 mm Photo 3 Table 2 72 4.2.2 590 MPa 3 Photo 4 PRB 3 590 MPa φ65 t3.8 mm Photo 4 5.

6 Table 2 Merits by applying 780 MPa class ERW tube to automotive part bent by PRB method Items Press formed part (Steel sheet) Bent and hydraulic formed part (ERW tube) Total number of production process (Forming and welding) 100% 28% 72% Number of assembled parts 100% 71% 29% Weight/One part 100% 82% 18% Cost/One part 100% 74% 26% Merits Photo 3 Automotive part applied PRB method and 780 MPa class ERW tube Si Fig PRB Photo MPa MPa 780 MPa PRB φ70 t 2.6 mm Photo 3 Table MPa 3 Photo 4 PRB MPa φ65 t3.8 mm Photo 4 5. Automotive part applied PRB method and 590 MPa class ERW tube PRB R MPa PRB 780 MPa R THF 1 CAMP-ISIJ 2003 vol. 16 p vol. 46 no. 534 p vol. 46 no. 534 p H p Schubert, Paul B. Pipe and Tube Bending, The Industrial Press JFE No

6 Fuchs, F. J. JR. The Bell System Technical Journal. 1959, vol. 38, no.

313 p. 123 127 9 2 1992 10 10 1998-10 vol. 39 no. 453 p. 1008 11 W.-D.

475 478 13 1994 vol. 35 no. 398 p. 262 267 14 Neugebauer, W.-G. et al.

15 Tozawa, Y. et al. Annals of the CIRP. vol. 33/1, 1984, p. 175 178.

285 288. 17 56 2005 p. 191 192 18 56 2005 p. 193 194 19 56 2005 p.

7 6 Fuchs, F. J. JR. The Bell System Technical Journal. 1959, vol. 38, no. 6, p vol. 10 no. 103 p vol. 28 no. 313 p vol. 39 no. 453 p W.-D. Franz. Springer Verlag Berlin/Gottingen/ Heidelberg, H p vol. 35 no. 398 p Neugebauer, W.-G. et al. Advanced Technology of Plasticity. 2002, vol. 2, p Tozawa, Y. et al. Annals of the CIRP. vol. 33/1, 1984, p Tozawa, Y.; Ishikawa, T. Annals of the CIRP. vol. 37/1, 1988, p p p p JFE 2004 no. 4 p vol. 7 no. 11 p CAMP-ISIJ 2005 vol. 18 p JFE No

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