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ECOLE DES MINES D ’ALBI

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ecole des mines d albi research centre on tools, materials and processes cromep cromep_2000_eng _lp_i 6-00 french ecole des mines network 7 schools financed and ... – PowerPoint PPT presentation

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Title: ECOLE DES MINES D ’ALBI


1
ECOLE DES MINES D ALBI
  • RESEARCH CENTRE ON TOOLS, MATERIALS AND
    PROCESSESCROMeP

CROMeP_2000_eng _LP_I 6-00
2
FRENCH ECOLE DES MINES NETWORK
BELGIUM
Bruxelles
  • 7 schools
  • Financed and run directly
  • by Ministery of Industry

GERMANY
Douai
PARIS
Frankfort
Nancy
Nantes
SWITZERLAND
Geneva
650 km
ITALY
Lyon
Saint Etienne
Milano
Bordeaux
Alès
Albi
Montpellier
Toulouse
250 km
SPAIN
Barcelone
3
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

4
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

5
TEAM
  • In 12/17/99 45 persons
  • 18 scientists engineers
  • 5 technicians
  • 2 secretaries
  • 19 Ph.D. students
  • 2 Post-Doc

6
PLURIDISCIPLINARY APPROACH
Process flow simulation
Material Processes - metals - polymers -
glasses - ceramics - composites - ...
Microstructure Damage Characterization
Thermo-mechanical analysis of molds, dies and
tools (FE).
Thermal Mechanical analysis of tools -
undersdanding - optimisation - prevision
Material Testing Tool coating testing
Mold, dies tools testing on pilot plants
Physical characterization of materials
Computer vision applied to process control
Thermal monitoring of industrial equipments
Infra Red Thermography
Non destructive testing
Surface treatment, coating lubrification
7
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

8
TEST FACILITIES
  • 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
  • Mechanical
  • isothermal fatigue (1200C)
  • 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)

9
RESEARCH CONTRACT ORIGINS
  • Industrial contracts
  • Regional
  • National
  • European Community

10
MANPOWER RESOURCES AND RESULTS
11
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

12
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

13
Mechanical properties behaviour laws
measurements
Thermomecanical stress during fatigue test
at 500C and 900C
Carbide micro-crack after monotonic load at 500C
Superplatic forming
Choi, Baleix, Bernhart, Lours
14
Cracks, thermal mechanical damage identification
Uniaxial and biaxial crack during thermal
fatigue
Temperature effect on the thermomechanical
life
Forging
Jean, Oudin, Miquel, Rezai-Aria
15
Assessment of the process induced sollicitations
Numerical simulation of forging operation with
FORGE2
Critical area prediction and time life
Fatigue life calculated
Forging
Oudin, Penazzi, Rezai-Aria
16
Development of interconnections beetween process
tool
Thermo-elastic stress during aluminum casting
mold 240C - Al 750C
Cracks in casting mold Mold cast-iron
Baroucaire, Michrafy, Dour
Casting
17
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
18
Microstructure and behavior of reinforced
concretes
  • Dilation evolution of refractory concrete
    reinforced by metallic fibers

Prototype insert moulds
Cailleux, Cutard, Bernhart
Superplastic forming
19
Infrared heating of thermoplastic preform
  • Temperature contours of preform and lighters
    during heating

Modeling of preform heating
Thermoplastic heating
Monteix, Le Maoult, Schmidt
20
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

21
Thermal and mechanical test equipments
  • Thermomecanical fatigue machine Thermal fatigue
    rig

Material behaviour laboratory
22
Tribology and wear test facilities
  • HT Tribometer equipement Friction
    coefficient variation with sliding
    length for 35NCD16 steel

Without oxydation Pre-oxydation
400C Pre-oxydation 750C
Time (s)
Tribology laboratory
Boher, Vergne
23
Sheet metal forming tools wear resistance
Sheet metal forming pilot
Tools geometries Strain gages and
thermocouples instrumented tools 3-axials
force cell
5 KN - 150 mm/s - continuous or 10 cycles/min -
coil 200 kg
Technical Hall
Boher, Lamesle, Penazzi
24
Injection facilities
  • Injection moulding machine with modular molds

Technical Hall
Wesselman, Saint-Martin, Devos
25
Heat treatment quench facility
Shape variations monitoring for Austenitic
Stainless Steel X2CrNi18-9 during cooling
  • Heat treatment
  • vacuum furnace quenching

End 135s 55s 50s 225s
110s 25 s
Thermal and surface traitement laboratory
Claudinon Lamesle, Orteu
26
International Network on Forming Tools Research
and Development
  • 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,

27
International Network on Forming Tools Research
and Development
  • 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 levaillant_at_enstimac.fr
  • http//www.enstimac.fr/

28
International Network on Forming Tools Research
and Development
  • 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

29
EXCHANGE OFFERS
  • Post-doc students
  • mechanical and materials sciences
  • work proposed
  • sheet metal forming tools (material, coating,
    wear)
  • tribology at high temperature
  • Visiting professors
  • mechanical and material sciences
  • at least 6 months
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