Correlation and optimization of theoretical 3D laser cutting simulation

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

Gestamp HardTech in Luleå is part of the global Gestamp group which develops and produces components for the automotive industry. Gestamp HardTech has plenty of well-known customers and specializes in the production of press hardened components.

With the global aim of reducing CO₂ emissions and increasing safety for the next generation of vehicles there is a need of innovative design and lightweight solutions, in which the press hardening process has a key role. Gestamp HardTech was the first ever production plant working with press hardening and has a wide experience and expertise together with an in-house R&D center that supports Gestamp globally.

Background
TechCenter is one of the R&D groups in Luleå, working with definition and optimization of production planning for press hardened parts within the global Gestamp concern. The documentation provided from TechCenter to internal sales departments acts as a foundation for all global press hardening quotations provided from Gestamp. Needless to say, accurate calculations and simulations are of outmost importance to provide accurate quotations to Gestamp’s customers.

A press hardened component is manufactured from a flat sheet of steel, shaped with massive presses into the desired shape. Commonly, the flat sheet will have some additional material added depending on i.e. customer tolerances and shape complexity of the final part. One of the main cost impacts for a press hardened component is to then in a secondary operation remove this excess material, using 3D laser cutting machines.

Achieving the time required for this operation is currently formula based. However TechCenter is working on implementing a simulation based method of evaluating a 3D-geometry to further improve the accuracy of the laser cycle time evaluation. However, initial correlation tests indicate a substantial discrepancy between simulated values and actual values from production.

Goals
Perform additional correlation studies based on real life production results. This benchmarking should be carried out both through comparison with existing simulation tools from Gestamp’s laser machine supplier as well as physical testing in real-world conditions. After testing, an optimization of TechCenter’s in-house developed laser cutting evaluation should be performed.

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 be a middleman between the theoretical world on R&D and the real world out in the environment of an actual production plant.

Time and duration
30 hp with start in 2025.

Contact
Dennis Bröms
Team Leader R&D TechCenter
dbroms@se.gestamp.com
073 661 45 57

www.gestamphardtech.se