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MACRODYNE HYDRAULIC PRESSES
AEM & Macrodyne Gas Oscillation Super Plastic Forming (GO-SPF)
Company Profile: Overview & Product Areas
Presses
&
Automation
Hydraulic Presses from 50 – 30,000 Tons
Turnkey Hydraulic Press Lines
Custom Press Line Automation
Automated Die Storage & Retrieval Systems
Die Carts, Die Elevators Die Transfer Tables, Rolling
Bolsters
Die Storage Racks, Die Carrier Plates, Die Clamping
Packages
Die Handling
Service &
Retrofits
Retrofits, rebuilds & upgrades for all brands of hydraulic presses
Preventative maintenance, trouble-shooting & repair services
Spare & replacement parts
 Over 30 years in business, $100M+ Revenue, 150+ Employees Globally
 Presses supplied to North & South America, Europe and Asia
 Manufacturing & service locations in Canada, USA and Germany
 Service Partners: UK, Mexico, Additional Capacity in USA
 Our Global Presence:
 North America – Macrodyne Technologies Inc (Canada and USA)
 Europe- Asia - Dunkes (A Macrodyne company in Germany)
Partnership
 AEM has developed novel patented technology to drastically increase maximum strain and
decrease cycle times during forming by an order of magnitude
 TRL 8 demonstration is happening early spring with commercialization to follow immediately after
 Currently working with early adaptors in industries including: Marine, Aerospace, Automotive, and
Consumer Goods
 Key highlights:
 Forming up to 20x faster than traditional SPF
 More complex and detailed features than traditional SPF
 Able to make traditional stamped parts in one process instead of progressive die or multiple
parts with welding
Gas Oscillation Forming Technology
for
Oscillation Enhanced SPF
Why Improve SPF ?
Slow forming time
3 - 25 minutes - Automotive panels
1 - 8 hours - Aerospace panels
How to Improve SPF ?
Improve Forming Tool “Gas” – compressible fluid
Gas can be Oscillated to act as a Hammer
In Process Dynamic Stress Relieve with minor gas oscillations
In Process Dynamic Stress Relieve
Each generated minor gas oscillation deforms the material
and subsequently allows for partial stress relieve
Pressure
Time Improved grain boundary
sliding mechanism
Pressure
Time
SPF OESPF
Intellectual Property
US & Canadian Patent
EU Patent Pending Approval
New Patent Application July 2022
Gas Oscillation Forming Technology
R&D 2009 – 2021
Metal Forming
Fluid Dynamics
AEM & Macrodyne –
NGen.ca
Collaborative Technology
Demonstration Project
Gas Oscillation Forming
System
Commercialization 2023
Gas Oscillation Forming System
Metal Forming Fluid Dynamics
 Material characterization at various
amplitudes and frequencies
 Development of constitutive model
 FEA simulation with oscillation
 Design of Gas Oscillation Forming System
with Supersonic Fluidic Oscillator to
generate minor gas oscillations of required
frequency and amplitude to match FEA
part simulations
• Tool Design dependent
• Part Geometry dependent
• Forming Material dependent
Demonstration Project AA5083 1.4mm thick
Wide......
Long…...
Height….
825 mm (32.50”)
870 mm (34.25”)
616 mm (24.25”)
2 Cavity Tool
300
0
50
100
150
200
250
300
350
400
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0 50 100 150 200 250 300
Pressure
(Psi)
Strain
rate
(
1/second)
Time (seconds)
FEA Simulation SPF AA5083
60 90 150
120 180 240
0
50
100
150
200
250
300
350
400
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0 50 100 150 200 250 300
Pressure
(Psi)
Strain
rate
(
1/second)
Time (seconds)
150
60 90 150
120 180 240
300
300
0
50
100
150
200
250
300
350
400
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0 50 100 150 200 250 300
Pressure
(Psi)
Strain
rate
(
1/second)
Time (seconds)
FEA Simulation SPF AA5083
Limit
60 90 150
120 180 240
0
50
100
150
200
250
300
350
400
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0 50 100 150 200 250 300
Pressure
(Psi)
Strain
rate
(
1/second)
Time (seconds)
150
Peak Strain Rate
During forming
Entire Part
120
90
60
180
240 300
60 90 150
120 180 240
300
FEA Simulation SPF vs OESPF AA5083
0
50
100
150
200
250
300
350
400
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0 5 10 15 20 25 30 35 40 45 50 55 60
Pressure
(Psi)
Strain
rate
(1/second)
Time (seconds)
60
Limit
SPF
60
60
16 19 25 32 44
62
0
50
100
150
200
250
300
350
400
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0 5 10 15 20 25 30 35 40 45 50 55 60
Pressure
(Psi)
Strain
rate
(1/second)
Time (seconds)
60
Limit
SPF
32
25
16 19
16 19 25 32 44
62
FEA Simulation SPF vs OESPF AA5083
0
50
100
150
200
250
300
350
400
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0 5 10 15 20 25 30 35 40 45 50 55 60
Pressure
(Psi)
Strain
rate
(1/second)
Time (seconds)
60
Limit
SPF
60
60
16 19 25 32 44
62
0
50
100
150
200
250
300
350
400
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0 5 10 15 20 25 30 35 40 45 50 55 60
Pressure
(Psi)
Strain
rate
(1/second)
Time (seconds)
60
Limit
SPF
32
44
62
25
16
19
16 19 25 32 44
62
Limit
OESPF
FEA Simulation AA5083 1.4 mm Thickness
SPF
240 seconds forming time
54% thickness reduction
0.1/s Peak Strain Rate
SPF
300 seconds forming time
45% thickness reduction
0.05/s Peak Strain Rate
54 %
45 %
OESPF
16 seconds forming time
43% thickness reduction
0.16/s Peak Strain Rate
43 %
OESPF more uniform
thickness distribution
FEA Simulation – Maximum Von Mises Stress
OESPF
16 seconds forming time
0.16/s Peak Strain Rate
SPF
300 seconds forming time
0.05/s Peak Strain Rate
OESPF
part formed at
lower stresses
higher strain rates
74 MPa
83 MPa
FEA Simulation Summary AA5083
OESPF SPF
Time to reach 50% thickness
OESPF process improves material grain boundary sliding mechanism
through in Process Dynamic Stress Relieve leading to more homogenous
stress distribution with the following potential benefits:
• reduces forming time
• increases elongation
• improves thickness uniformity
• reduces localized peak stresses
• operate at higher strain rates
• more economical process
- 16 sec 250 - 300 sec
Thank You!
Contact Info:
Kevin Fernandes
President
Macrodyne Technologies Inc.
www.macrodynepress.com
905 669 2253 x 301
kfernandes@macrodynepress.com

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GROUND-BREAKING LIGHTWEIGHTING TECHNOLOGY FOR ALUMINUM AUTOMOTIVE PARTS

  • 1. MACRODYNE HYDRAULIC PRESSES AEM & Macrodyne Gas Oscillation Super Plastic Forming (GO-SPF)
  • 2. Company Profile: Overview & Product Areas Presses & Automation Hydraulic Presses from 50 – 30,000 Tons Turnkey Hydraulic Press Lines Custom Press Line Automation Automated Die Storage & Retrieval Systems Die Carts, Die Elevators Die Transfer Tables, Rolling Bolsters Die Storage Racks, Die Carrier Plates, Die Clamping Packages Die Handling Service & Retrofits Retrofits, rebuilds & upgrades for all brands of hydraulic presses Preventative maintenance, trouble-shooting & repair services Spare & replacement parts  Over 30 years in business, $100M+ Revenue, 150+ Employees Globally  Presses supplied to North & South America, Europe and Asia  Manufacturing & service locations in Canada, USA and Germany  Service Partners: UK, Mexico, Additional Capacity in USA  Our Global Presence:  North America – Macrodyne Technologies Inc (Canada and USA)  Europe- Asia - Dunkes (A Macrodyne company in Germany)
  • 3. Partnership  AEM has developed novel patented technology to drastically increase maximum strain and decrease cycle times during forming by an order of magnitude  TRL 8 demonstration is happening early spring with commercialization to follow immediately after  Currently working with early adaptors in industries including: Marine, Aerospace, Automotive, and Consumer Goods  Key highlights:  Forming up to 20x faster than traditional SPF  More complex and detailed features than traditional SPF  Able to make traditional stamped parts in one process instead of progressive die or multiple parts with welding
  • 4. Gas Oscillation Forming Technology for Oscillation Enhanced SPF
  • 5. Why Improve SPF ? Slow forming time 3 - 25 minutes - Automotive panels 1 - 8 hours - Aerospace panels How to Improve SPF ? Improve Forming Tool “Gas” – compressible fluid Gas can be Oscillated to act as a Hammer In Process Dynamic Stress Relieve with minor gas oscillations
  • 6. In Process Dynamic Stress Relieve Each generated minor gas oscillation deforms the material and subsequently allows for partial stress relieve Pressure Time Improved grain boundary sliding mechanism Pressure Time SPF OESPF
  • 7. Intellectual Property US & Canadian Patent EU Patent Pending Approval New Patent Application July 2022
  • 8. Gas Oscillation Forming Technology R&D 2009 – 2021 Metal Forming Fluid Dynamics AEM & Macrodyne – NGen.ca Collaborative Technology Demonstration Project Gas Oscillation Forming System Commercialization 2023
  • 9. Gas Oscillation Forming System Metal Forming Fluid Dynamics  Material characterization at various amplitudes and frequencies  Development of constitutive model  FEA simulation with oscillation  Design of Gas Oscillation Forming System with Supersonic Fluidic Oscillator to generate minor gas oscillations of required frequency and amplitude to match FEA part simulations • Tool Design dependent • Part Geometry dependent • Forming Material dependent
  • 10. Demonstration Project AA5083 1.4mm thick Wide...... Long…... Height…. 825 mm (32.50”) 870 mm (34.25”) 616 mm (24.25”) 2 Cavity Tool
  • 11. 300 0 50 100 150 200 250 300 350 400 0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0 50 100 150 200 250 300 Pressure (Psi) Strain rate ( 1/second) Time (seconds) FEA Simulation SPF AA5083 60 90 150 120 180 240 0 50 100 150 200 250 300 350 400 0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0 50 100 150 200 250 300 Pressure (Psi) Strain rate ( 1/second) Time (seconds) 150 60 90 150 120 180 240 300
  • 12. 300 0 50 100 150 200 250 300 350 400 0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0 50 100 150 200 250 300 Pressure (Psi) Strain rate ( 1/second) Time (seconds) FEA Simulation SPF AA5083 Limit 60 90 150 120 180 240 0 50 100 150 200 250 300 350 400 0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0 50 100 150 200 250 300 Pressure (Psi) Strain rate ( 1/second) Time (seconds) 150 Peak Strain Rate During forming Entire Part 120 90 60 180 240 300 60 90 150 120 180 240 300
  • 13. FEA Simulation SPF vs OESPF AA5083 0 50 100 150 200 250 300 350 400 0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0 5 10 15 20 25 30 35 40 45 50 55 60 Pressure (Psi) Strain rate (1/second) Time (seconds) 60 Limit SPF 60 60 16 19 25 32 44 62 0 50 100 150 200 250 300 350 400 0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0 5 10 15 20 25 30 35 40 45 50 55 60 Pressure (Psi) Strain rate (1/second) Time (seconds) 60 Limit SPF 32 25 16 19 16 19 25 32 44 62
  • 14. FEA Simulation SPF vs OESPF AA5083 0 50 100 150 200 250 300 350 400 0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0 5 10 15 20 25 30 35 40 45 50 55 60 Pressure (Psi) Strain rate (1/second) Time (seconds) 60 Limit SPF 60 60 16 19 25 32 44 62 0 50 100 150 200 250 300 350 400 0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0 5 10 15 20 25 30 35 40 45 50 55 60 Pressure (Psi) Strain rate (1/second) Time (seconds) 60 Limit SPF 32 44 62 25 16 19 16 19 25 32 44 62 Limit OESPF
  • 15. FEA Simulation AA5083 1.4 mm Thickness SPF 240 seconds forming time 54% thickness reduction 0.1/s Peak Strain Rate SPF 300 seconds forming time 45% thickness reduction 0.05/s Peak Strain Rate 54 % 45 % OESPF 16 seconds forming time 43% thickness reduction 0.16/s Peak Strain Rate 43 % OESPF more uniform thickness distribution
  • 16. FEA Simulation – Maximum Von Mises Stress OESPF 16 seconds forming time 0.16/s Peak Strain Rate SPF 300 seconds forming time 0.05/s Peak Strain Rate OESPF part formed at lower stresses higher strain rates 74 MPa 83 MPa
  • 17. FEA Simulation Summary AA5083 OESPF SPF Time to reach 50% thickness OESPF process improves material grain boundary sliding mechanism through in Process Dynamic Stress Relieve leading to more homogenous stress distribution with the following potential benefits: • reduces forming time • increases elongation • improves thickness uniformity • reduces localized peak stresses • operate at higher strain rates • more economical process - 16 sec 250 - 300 sec
  • 18. Thank You! Contact Info: Kevin Fernandes President Macrodyne Technologies Inc. www.macrodynepress.com 905 669 2253 x 301 kfernandes@macrodynepress.com

Notes de l'éditeur

  1. Focus for now Aerospace Automotive Markets
  2. Talk about Next Generation Manufacturing Canada award and project
  3. Prototype Tool
  4. Pressure Time curves Reduce until reach 50% thickness reduction or 0.05 /s strain rate Peak Strain Rate is measured anywhere in the part during the forming process not at one location
  5. Pressure Time curves Reduce until reach 50% thickness reduction or 0.05 /s strain rate Peak Strain Rate is measured anywhere in the part during the forming process not at one location
  6. OESPF Uses different generated pressure time curves that are reduced until we reach 50% thickness reduction or 0.20 /s strain rate Part is formed in 8 seconds of the 16 second forming cycle
  7. OESPF Uses different generated pressure time curves that are reduced until we reach 50% thickness reduction or 0.20 /s strain rate Part is formed in 8 seconds of the 16 second forming cycle
  8. Future tool modifications are planned with more complex part surface geometry with detailed features and sharper corners OESPF process allows for more uniform thickness distribution