Lasers in Engineered Welded Blanks

Lasers in Engineered Welded Blanks
Shiloh Industries, Inc.
Shiloh Industries, Inc.
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Company Overview
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Established in1950
1,200 employees
Publicly traded as “SHLO” on NASDAQ Exchange
FY 2011 Sales - $518 million
TS16949 approved – All Plants
9 operations in United States & Mexico
Shiloh Capabilities Include:
• Tool & Die Development
• Coil Processing
• Precision Blanking
• Engineered Welded Blanks
• Complex Stamping & Modular Assemblies
• Deep Draw Capabilities
• AcroStikTM Laminate Solutions
Shiloh Industries, Inc.
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Geographic Locations
Medina Blanking
OH, USA
Liverpool Coil Processing
OH, USA
Canton Manufacturing;
Sales & Technical Center,
MI, USA
Engineering, Blanking,
EWB, Laser Cutting
Engineering, Blanking, EWB,
Stamping, Modular Assembly
Coil processing (slitting & CTL),
Stamping, Modular Assembly,
AcroStikTM
Wellington Manufacturing
OH, USA
Ohio Welded Blank
OH, USA
Complex Stamping,
Modular Assembly
Blanking, EWB, AcroStikTM
Bowling Green Manufacturing
KY, USA
Jefferson Manufacturing
GA, USA
Dickson Manufacturing
TN, USA
Heavy Gauge Blanking,
Stamping
Blanking, EWB,
Stamping
Complex Stamping,
Modular Assembly
Shiloh de Mexico
Ramos Arizpe, Mexico
Blanking, EWB,
Stamping,
Modular Assembly
Shiloh Industries, Inc.
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Product Applications
Shiloh Industries, Inc.
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First Operation Blanking
Shiloh Industries, Inc.
First Operation Blanking
Shiloh Industries, Inc.
Laser Process Capabilities
Engineered Welded Blanks (EWB)
Engineered Welded Blanks are more advanced laser welded blanks,
manufactured from two or more blanks of the same or different steel grades
or gauges welded together. A high level of engineering analysis and laser
technology is applied to achieve a reduction in vehicle mass, number of
parts, and tooling cost, while improving body strength.
It is important to note, that unlike other welding applications, a welded blank
will be formed after welding. The stresses applied during the forming process
require a very high quality weld placed in the exact location to optimize mass
and material utilization.
Shiloh Industries, Inc.
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Why do we use Engineered Welded Blanks?
Different gauges, materials & coatings can be incorporated into one
blank
 Blank can be engineered to desired properties
Consolidation of components
 Reduction in number of parts
 Reduced tooling costs
 Reduced assembly operations and equipment
Material utilization
 Reduction in engineered scrap due to improved blank nesting
Mass reduction on vehicle
Shiloh Industries, Inc.
Shiloh EWB History
Engineered Welded Blank Capabilities
• Started Engineered Welded Blank production in 1989
• First welded blank was mash seam welded
• Reclamation of offal from large body blanks
• Moved to laser welding in 1994
• Current production est. 10,000,000 EWB/yr
• 5 EWB facilities currently
Shiloh Industries, Inc.
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Linear Welded Components
Underbody
Components
Door Inners
Body Side Inners
Shiloh Industries, Inc.
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Multi-Linear Welded Components
Rear Door
Inner (Draw)
Rear Door
Inner (Final)
Body Side Inner
Shiloh Industries, Inc.
Lift Gate Inner
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Curvilinear Welded Components
Shiloh Industries, Inc.
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Advantages of Laser Welding
• Improved speed and flexibility
• Common systems with interchangeable fixtures
• Improved weld quality
• Smaller HAZ
• Reduced work piece distortion
• Improved formability
• Better material utilization
• No overlap or flange required
• One side access
• Enhanced capabilities for curvilinear welding
Shiloh Industries, Inc.
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Applications
• Material Optimization – Reduction in Engineered Scrap
Current Design
1727 mm
68.750”
Total Material usage = 32.66 kg
63.843”
1600
mm
Three Piece Even gage EWB Design
Total Material usage = 26.33 kg
Advantages
 6.33 kg material savings per part
 Blank A and B can be uncoated
Shiloh Industries, Inc.
Applications
• Part Consolidation
Blank A,
2 Pc. Baseline Design
EWB Option
Material Usage 5.23 kg
Material Usage 4.38 kg
On Vehicle Mass 2.74 kg
On Vehicle Mass 2.38 kg
Blank B,
Advantages
• 0.84 kg of Material savings per side
Reinforcement
• 0.36 kg of mass savings on vehicle per side
• Lower stamping die cost
Pillar ,
• No welding or fixture costs
• Lower press time, transportation, inventory
Shiloh Industries, Inc.
Balance - Formability & Mass Savings
Thinning
Blank
Vehicle mass optimization example:
For some applications the part geometry requires a high level of material
elongation for forming. Placement of the weld seam is critical. This example
shows a solution to achieve acceptable levels of material thinning by correct
placement of the weld line and mass optimization with curvilinear laser weld.
40 %
Shiloh Industries, Inc.
30 %
15 %
15 %
Applications
• Vehicle Mass Optimization
Base Design
Blank
Curvilinear Weld Option
Mass in kg
Thick
Blue
4.75
Thin
Green
4.59
Total
Shiloh Industries, Inc.
9.34
Blank
-1.1 Kg /Door
Mass Savings
Mass in kg
Thick
Pink
2.75
Thin
Brown
5.48
Total
8.23
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Applications
• Lightweight Opportunities
Lift gate Inner and Reinforcements
4-Pc Curvilinear EWB Proposal
Blank A
Blank B
Blank C
Blank D
Advantages
• Eliminates 4 parts, 2 stamping dies and 1 blank die
• Steel Savings of 5.45 kg.
• Mass savings of 0.90 kg on vehicle
Shiloh Industries, Inc.
Laser Welding Keys to Success
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Training
Laser Champion(s)
Inventory of key maintenance items
Quality fit up of components
Good fixture design
Shiloh Industries, Inc.
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Future Applications
• Laser Welding of Advanced materials
• AHHS coated & uncoated
• PHS coated & uncoated
– Laser Removal (ablation) of coatings
• Aluminum
• Fiber reinforced Plastics
• Laser Welded Coils
• Highly Engineered Welded Blanks
• EWB with addition of Acoustic/structural patches
• Heavy Gage Frame (class 8 trucks)
Shiloh Industries, Inc.
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Shiloh Industries, Inc.
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