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CR MeP
ECOLE DES MINES D ’ALBI
RESEARCH CENTRE ON TOOLS, MATERIALS AND
PROCESSES
CROMeP
CROMeP_2000_eng _LP_I 6-00
CR MeP
7 schools Financed and run directly
by Ministery of Industry
FRENCH ECOLE DES MINES NETWORK
PARIS
Toulouse •
• Bordeaux
• Montpellier
Douai •
Nantes
• Alès
Nancy
• Saint Etienne
SPAIN
BELGIUM
GERMANY
SWITZERLAND
ITALY650
km
Albi
• Lyon
• Bruxelles
Barcelone •
250
km
• Frankfort
• Geneva
Milano •
CR MeP Centre de Recherche sur les Outillages, les Matériaux et les
Procédés
Research Center on Tools, Materials and Processes
Founded in 1993
Industrial oriented research global approach for tooling and processes problems
Research on tool materials used in
forging, casting, hot rolling, sheet metal forming, superplastic forming, injection molding, glass industry, etc
CR MeP WHY THIS THEME ?
Significant ecomical impact in material industry direct : raw materials, machining, treatment indirect : cost saving, product quality, productivity
R &D in a industrial company Partially activity Tool manufacturing is often subcontracted Diversification of professions Multidisciplinary problems
CR MeP TEAM
In 12/17/99 : 45 persons
18 scientists & engineers
5 technicians
2 secretaries
19 Ph.D. students
2 Post-Doc
CR MeP PLURIDISCIPLINARY APPROACH
Microstructure &Damage
Characterization
Thermal & Mechanical analysis of tools
- undersdanding - optimisation
- prevision
Material Processes- metals - polymers- glasses - ceramics
- composites - ...
Material TestingTool coating testing
Physical characterizationof materials
Non destructive testing
Surface treatment,coating & lubrification
Process & flow simulation
Thermo-mechanical analysisof molds, dies and tools (FE).
Mold, dies & tools testingon pilot plants
Computer vision appliedto process control
Thermal monitoring of industrialequipments; Infra Red
Thermography
CR MeP 4 SCIENTIFIC RESEARCH AXIS
Measurement of tool sollicitations Heat flux, temperatures and displacements
Contact less measurement technics (CCD cameras, infra-red)
Behaviour and reliability of tool materials Material behaviour and modeling
Isothermal and non-isothermal
Surfaces Performance reliability of tools surfaces
Thermomechanical fatigue life, wear and damage
Modeling and design of tools Coupled or un-coupled mechanical, thermal and chemical modelling
CR MeP TEST FACILITIES
• Mechanical• 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
• Microstructural analysis• 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)
• Portable monitoring equipments• infra red cameras (3-5µm & 8-12µm)
• thermocouple acquisition system
• image acquisition (C.C.D.)
• Pilot plants• thermoplastic injection
• Aluminium casting equipment
• Wear in sheet metal forming
• Thermal treatment
• Software• 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
CR MeP MANPOWER RESOURCES AND RESULTS
Research turnover (Million of FF)
1,1
3,3
1,9 2
3,7
00,5
11,5
22,5
33,5
4
1995 1996 1997 1998 1999
CR MeP RESEARCH APPROACH
Two basic orientations
• A-Laboratory scale : Materials characterization and
assessment
• B-Pilot scale : Reproduce and simulate phenomena
to reach scientific unterstanding and develop the behaviour and
life prediction models
CR MeP 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
Development of interactions between processes and tools
2-Monitoring & identification of industrial equipment
operating parameters with mobile equipments Stereovision rigs
CR MeP
Carbide micro-crack after monotonic load at 500°C
Thermomecanical stress during fatigue test at
500°C and 900°C
Choi, Baleix, Bernhart, Lours Superplatic forming
Mechanical properties & behaviour laws measurements
CR MePCracks, thermal & mechanical
damage identification
Uniaxial and biaxial crack during thermal fatigue
Temperature effect on the thermomechanical life
Jean, Oudin, Miquel, Rezai-Aria Forging
CR MeP Assessment of the process induced sollicitations
Numerical simulation of forging operation
with FORGE2Fatigue life calculated
Oudin, Penazzi, Rezai-Aria
Critical area prediction and
time life
Forging
CR MeP Development of interconnections beetween process & tool
Cracks in casting mold
Mold : cast-iron
Baroucaire, Michrafy, Dour
Thermo-elastic stress during aluminum casting
mold : 240°C - Al : 750°C
Casting
CR MeP Monitoring & identification parameters with stereovision rigs
3D shape measurement with stereocorrelation method 2D crack propagation an dfrfacture
thougnhess measurement during 3 points bending test
Garcia, Orteu, Rezai-Aria
CR MeP
Dilation evolution of refractory concrete
reinforced by metallic fibers
Microstructure and behavior of reinforced concretes
Cailleux, Cutard, Bernhart
Prototype insert moulds
Superplastic forming
CR MeP
Temperature contours of preform and lighters during
heating
Infrared heating of thermoplastic preform
Monteix, Le Maoult, Schmidt
Modeling of preform heating
Thermoplastic heating
CR MeP REPRODUCE & SIMULATE PHENOMENA
With classical or special designed test equipments Thermal and mechanical test equipments Tribology and wear test facilities
With instrumented industrial or pilot equipments Sheet metal forming tools wear resistance Plastic injection facilities Heat treatment and quenching facility
CR MeP Thermal and mechanical test equipments
Thermomecanical fatigue machine Thermal fatigue rig
Material behaviour laboratory
CR MeP Tribology and wear test facilities
HT Tribometer equipement Friction coefficient variation with sliding length for 35NCD16 steel
Tribology laboratory
Without oxydationPre-oxydation 400°CPre-oxydation 750°C
Boher, Vergne
Time (s)
CR MeP Sheet metal forming tools wear resistance
Technical Hall
Sheet metal forming pilot Tools geometries
Strain gages and thermocouples instrumented tools
3-axials force cell5 KN - 150 mm/s - continuous or 10 cycles/min - coil : 200 kg
Boher, Lamesle, Penazzi
CR MeP
Technical Hall
Injection facilities
Injection moulding machine with modular molds
Wesselman, Saint-Martin, Devos
CR MeP Heat treatment & quench facility
Thermal and surface traitement laboratory
Heat treatment
vacuum furnace quenching
End 135s 55s 50s 225s 110s 25 s
Shape variations monitoring for Austenitic Stainless Steel X2CrNi18-9 during cooling
Claudinon Lamesle, Orteu
CR MeP
Aim 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
forging, superplastic forming sheet metal forming casting, injection moulding,
International Network on Forming Tools Research and Development
CR MeP
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/
International Network on Forming Tools Research and Development
CR MeP
Cases of sheet metal forming tools 75 references papers from 1997 to 1999
Main country : France, Germany, USA, etc
Main actors : Aalborg Univ., Hanovre Univ., MIT, Ohio State Univ., TNO, etc
Main topics : Friction, design, material, tool
technology, etc
International Network on Forming Tools Research and Development
BH2%
design15%
friction24%
material13%
tool technol.
11%
computer simulat.
10%
coating.8%
economic5%w ear
8%
control2%
manufact.2%