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Development of a methodology for lightweight design of warm formed components with complex geometries for heavy vehicle applications. A project funded by RFCS.

WarmLight aims at developing a methodology for simulation based design of thick-walled components for trucks and other heavy machinery in the transport sector. The objective is to enable weight-optimized components with complex geometries, meeting fatigue properties by avoiding assemblies and welds / joints. The methodology of warm forming and a FE-simulation based forming process design is applied with new UHSS steel grades for warm forming. A process chain is defined in which the new steel grades are combined with down-stream thermo-mechanical processes. The methodology will be fully supported by modeling and simulation, including microstructural predictions, forming simulations and final property assessments.

The project consortium consists of Luleå University of Technology (Coordinator), Sweden, Eurecat Center Technologic de Catalunya, Spain, voestalpine Stahl, Austria, Scania CV, Sweden, CRF Centro Ricerche FIAT, Italy, and CONEX Concurrent Engineering Experts, Sweden.

The objectives are to:

  • Develop a predictive simulation methodology that supports an optimal design of a warm forming process in order to meet the performance and lightweight demands of the HDV sector.
  • Optimize a thermo-mechanical forming process (warm forming) for manufacturing of components that meets the demands with respect to part geometry and strength
  • Evaluate and select three UHSS steel grades for hot forming of thick-walled components with complex geometries. The target levels of ultimate tensile strengths are above 750 MPa, above 980 MPa and above 1150 MPa, respectively, after warm forming.
  • Develop demonstrator components fulfilling stated requirements and with more than 15% weight reduction compared to traditional technologies
  • Perform a complete and detailed Life Cycle Analysis to validate the sustainability of the proposed solutions

The project started 2018-09-01 and ends 2022-02-28.

For more information contact Professor Mats Oldenburg, email , tel 070 3117556.