Data-driven design for forming feasibility

- Master Thesis at Gestamp HardTech in Luleå
Department: Research and Development, TechCenter

Gestamp R&D in Luleå is part of the global Gestamp group which develops and produces components for the automotive industry. Gestamp’s R&D office in Luleå currently employs around 60 engineers. With the aim of reducing CO₂ emissions and increasing safety for the next generation of vehicles there is a need of innovative design and lightweight solutions, where the press hardening process is one of used technologies.

TechCenter is responsible for process optimization for press hardened parts within Gestamp. The work is performed in close collaboration with our customers (e.g. VW, Toyota, Ford, GM, Tesla, and Volvo) as with our colleagues (e.g. Tool shops, Production plants). A big part of the daily routines is working with FEM and CAD software’s such as LS-DYNA, CATIA and NX to analyze forming feasibility.

Background
Common body structure parts often share the same type of limiting design features in certain areas. This can lead to unnecessary reiterative simulation work to find a feasible design for the press hardening process.

Goals
First part is to develop a framework for creating parametric base models of typical problematic areas on common parts. The goal is to learn which geometrical parameters that have the largest impact on formability with a suitable DOE-method. This work will be done using CAD software or mesh morphing with following FEM simulations in LS-DYNA and LS-OPT/LS-TaSC.

Second part is to investigate how the results can be used with the aim to help the product developer with decision making in the daily work. It may be with a software, other methods or with machine learning in mind.

Who are you?
A student in an engineering program with a technical focus such as mechanical engineering, industrial design or similar. You should have an interest in problem solving and a passion for technology.

What we offer

• A chance to work with state-of-the-art technology which will shape the future of the automotive industry
• The opportunity to learn the CAD and CAE tools which are used by the world’s leading car manufacturers
• Paid compensation

Time and duration
30 hp with start in 2025

Contact
Mattias Elfgren
Sr. Process Analyst R&D TechCenter
melfgren@se.gestamp.com 
070 237 90 42

www.gestamphardtech.se