High volume production of aluminum components: ALKOMP

Purpose and goal

The goal to shorten the lead time and cost of developing new aluminum components is achieved by reducing the number of iterations for die try-out. Improved FE analysis contribute to this goal. Properly tested material parameters in a suitable material model increases ability to predict the outcome significantly with FE simulation. Developed guidelines for trim and punching leads to less production disruptions and thereby contribute to the objective robust manufacturing. Detailed description is provided in appendices according to the FFI reporting instructions

Results and expected effects

The method for producing input data are evaluated for 5 different aluminium alloys. Evaluated friction model is implemented correctly, has full functionality and is computationally efficient. Based on the results from the semi-industrial cutting tests guidelines have been developed for today´s aluminum qualities. The basic requirement to obtain a more robust cutting process free from interference are a good spotting at the cutting edge and a controlled separation of scrap pieces. See Appendix 3

Approach and implementation

Friction conditions have been investigated and characterized. Friction Model has been implemented. Testing of the friction model and methodology for material characterization has been carried out for comparison with conducted experiments. Survey and analysis of industrial problems and monitoring of problems in production have been conducted. The results were used to develop recommendations for the development of a new process methodology applicable to cutting and punching of aluminum and a matrix of dominant parameters for chipping. See Appendix 3