The Road to No Wear: Stamping AHSS
Prof Bernard Rolfe
Director of Deakin Digital Design and Engineering Centre (3DEC) - Deakin University
Group Leader - Applied Computational Modeling - IFM - Deakin University
— All Welcome —
Prof Bernard Rolfe has been researching metal forming for the past 20 years. His focus has been on the forming of lightweight structures. Primarily he and his team have investigated stamping, but they have also studied other processes such as roll forming and, more recently, 3D printing.
The major change in stamping of parts for automotive body structures over the past two decades has been the incredible increase in the strength of the steel grades. At the turn of the millennium, typically HSLA grade steels were used with a strength of 400MPa to 500MPa. Currently, cold stamping of 1000MPa is almost typical, and hot stamping of Boron steel (1700MPa after quenching) is commonplace. The increase in sheet strength causes issues in cold stamping, such as increased springback and increased press tonnages, but it also leads to increased downstream effects like tool wear. The higher contact pressures have led to much more wear of stamping tooling.
Since 2006, Prof Rolfe and his team have been investigating tool wear in stamping. This has lead to modelling of the contact conditions at the tool/blank interface, investigating the wear mechanisms occurring during the stamping of AHSS, the initial development of galling models, and the development of a system to monitor the wear progression of a stamping tool.
This talk will review this work of the past 10 years to understand wear in stamping tooling.
Bernard Rolfe is currently a Professor (Advanced Manufacturing) in the School of Engineering at Deakin University. He was the Associate Head of School (Research) from 2014-2018, responsible for growing research and research culture in the School. During his leadership the School tripled its quality journal outputs per staff member, and almost doubled income and PhD numbers. His qualifications include a combined Economics and Engineering degree with honours in 1995 from the Australian National University (ANU), and a PhD in Advanced Manufacturing (ANU) in 2002. His research group has spent 20 years working on the use of advanced metals in sheet forming primarily for the automotive sector. He was the theme leader for lightweighting at the Australian Automotive Cooperative Research Centre (2014-2017), and he is currently on the Academic Advisory Board for the International Federation of Automotive Engineering. Bernard's current research focus is the design and forming of light weight structures, including the development of better constitutive models for materials. He is also investigating design techniques for lightweighting using additive manufacturing. Bernard has received four Vice Chancellor awards and has been part of over fifteen successful nationally competitive large research grants, totalling over AUD $22 million in awarded funds. He has published over 150 refereed articles.