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Extending light-weighting and mass-production of ultra high strength steels via condition-based maintenance

Pereira, Michael, Ubhayaratne, Kongalage Nishchitha, Voss, Brendan, Simon, Scott, Doolan, Matthew and Xiang, Yong 2015, Extending light-weighting and mass-production of ultra high strength steels via condition-based maintenance, in APAC 2015 : 18th Asia Pacific Automotive Engineering Conference : Meeting Regional Challenges with Global Technology, SAE International, Warrendale, Pa., pp. 1-6, doi: 10.4271/2015-01-0062.

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Title Extending light-weighting and mass-production of ultra high strength steels via condition-based maintenance
Author(s) Pereira, MichaelORCID iD for Pereira, Michael orcid.org/0000-0002-7885-5901
Ubhayaratne, Kongalage Nishchitha
Voss, Brendan
Simon, Scott
Doolan, Matthew
Xiang, Yong
Conference name 18th Asia Pacific Automotive Engineering. Conference ( 18th : 2015 : Melbourne, Aus)
Conference location Melbourne, Vic.
Conference dates 10-12 Mar. 2015
Title of proceedings APAC 2015 : 18th Asia Pacific Automotive Engineering Conference : Meeting Regional Challenges with Global Technology
Publication date 2015
Series APAC
Start page 1
End page 6
Total pages 6
Publisher SAE International
Place of publication Warrendale, Pa.
Summary The use of ultra high strength steels (UHSS) in the automotive industry presents a significant opportunity for continued vehicle light-weighting, due to possible strength-to-weight improvements of three to four times that of conventional sheet steel grades. This performance benefit is achievable whist maintaining most of the advantages of low-cost mass-production associated with the cold stamping of sheet steel for automotive body components. However, the introduction of UHSS can result in significantly increased wear of the stamping tools, which is difficult to predict at the design stage and can lead to unexpected process failure during mass-production. Therefore, there is a need to be able to monitor and predict the onset of severe wear, such that the best course of condition-based maintenance can be scheduled and unscheduled stoppages due to tool wear eradicated. This paper describes a novel active monitoring system that is being developed by researchers at Deakin University, The Australian National University and Ford Motor Company, Asia Pacific and Africa. The aim of the active monitoring system is to detect the initial onset of a change of state, such as wear, through the measurement of variables such as punch force and audio signals. A semi-industrial stamping process, using a progressive die setup and high strength steel sheet with hardened tool steel tooling, is the experimental basis for the initial model and system development.
ISSN 0148-7191
Language eng
DOI 10.4271/2015-01-0062
Field of Research 091006 Manufacturing Processes and Technologies (excl Textiles)
091008 Manufacturing Safety and Quality
Socio Economic Objective 861205 Sheet Metal Products
HERDC Research category E1 Full written paper - refereed
ERA Research output type E Conference publication
Grant ID LP120100239
Copyright notice ©2015, SAE International
Persistent URL http://hdl.handle.net/10536/DRO/DU:30074681

Document type: Conference Paper
Collection: School of Engineering
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