STEEL Online Training

STEEL ONLINE TRAINING

Since we have had to change the way we learn; the way we work; the way we administrate and the way we do business online training give an opportunity to continue and not miss an opportunity to keep on learning.

digicon has developed some of the unique PHS trainings as live online training to continue to support and meet your training needs.

With our online trainings, we can continue to support your employees, and yourselves with further education during the time of the shutdown.

Unfortunately, we cannot apply the hands-on part during E-Learning, but we will give and show you real live examples.

Our theoretical training is not only effective but is also distinguished within this field. Training modules are offered for materials, heating methods, forming, process know-how, tooling and measurement, as well for testing technologies. Our innovative and dedicated trainers provide expanded content and in-depth courses where you ask your questions and discuss them with the training group and the experts.

Level 1 - BASIC TRAINING (Online)

Description

The overall performance, the variety of methods and the high number of theoretical examples of the seminar are designed in a most helpful way for efficient learning. You will have the opportunity to be well versed with various parameter and experience Hot Sheet Metal Forming in a daily basis and acquire a deep insight and an efficient method of operating for this technology.

A detailed view about the topics will be given below. Although the range of the course is going from the state-of-the-art press hardening process to solution-based problem solving approaches and finishes with new innovative ideas in the hot forming sector.

Audience

Engineers, technicians and foremen in the fields of production, assembly, process planning QM & QS and technical sales.

Benefits

The overall performance and the variety of methods of the seminar are designed most helpful for efficient studying. You will have the opportunity to experiment with various parameters and experience Hot Sheet Metal Forming in the field and acquire a deep insight into the most efficient skills in technology.

Methods

digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players in the PHS-market.

Content

T1 – Fundamentals

As the topic header already suggests this chapter is all about the fundamentals for press hardening. It aims at creating a basic understanding what press hardening is and what the big advantages behind this technology are. The focus goes towards the automobile industry. Moreover, into the direction of crash performance and the usefulness of press hardened products in this field.

Crash performance

  • Steel banana
  • Specification of material strength classes
  • IIHS tests
  • UHSS product examples in the automobile industry

Press hardening methods

  • Direct press hardening
  • Indirect press hardening

T2 – Semi-finished Products (press hardenable materials)

This unit is all about the materials and coatings that can be effectively used for hot forming of steels. It gives a short overview about the material structures and alloy contents that need to be insured. The state-of-the-art material, the 22MnB5 is discussed and compared to new innovative ideas generated from the material- and coating point of view.

Fundamentals for press hardenable materials

  • Overview of the needed material structure – ZTU
  • Carbon content
  • Alloys

Boron alloyed steel – 22MnB5

  • Uncoated
  • Al-SI coated USIBOR1500P
  • Zinc coated
  • Diffusion and austenitisation

Non-corrosive stainless steel

Material combinations – tailor made materials (HSLA)

Further materials

T3 – Measurement Systems

Before going into the first practical unit of this seminar a knowledge about the current needed measurement systems in a hot forming process need to be discussed. Measurement systems are needed to guarantee a specific heating rate in the oven but also need to monitor the cooling rates during the forming process.

Overview of state of the art temperature measurement systems

  • Thermocouples
  • Pyrometer
  • Thermo camera

T3-1 – Heating fundamentals

Heating and cooling of press hardenable materials under different conditions

  • Metal sheet thickness
  • Transport times
  • Cooling on air
  • Temperature losses
  • Measurement system (Thermocouples, Thermo camera, Pyrometer)

T4 – Heating Technologies

There are various different heating possibilities for press hardening. Still, state of the art tells another story. Roller hearth furnaces are primarily used in the process chain of press hardening. A close look into this technology will be given in this unit. What is the operating principle? What is the efficiency of this technology? How can you calculate the needed energy for your products? Just to name some of the question that will be answered in this unit. Nevertheless also other heating technologies are discussed and compared to roller hearth furnace technology.

Fundamentals

  • Radiation
  • Convection
  • Heat transfer

State of the art roller hearth furnaces

  • Operating principle
  • Efficiency level
  • Energy recuperation
  • Advantages and disadvantages of this technology

Alternative heating concepts

  • Induction
  • Conduction
  • Indirect induction (flat iron principle)
  • Infrared

T5 – Tool- and Plant Technologies

Tool design plays a big role for hot forming because the cooling of the material during the forming process is the main reason for achieving a high strength product. The unit provides information about overall tool setup and design, different cooling strategies and materials and coatings used tool manufacturing. You experience the different units needed within the press hardening process, handling in-between the units and measurement systems which provide the quality of the process. Also a fundamental knowledge of different press designs is created within this unit.

Usefulness of cooled tools

Construction of a cooled tool

  • Monocoque construction
  • Segmented construction
  • Rapid-Tooling
  • Casted construction

Tool raw materials & surface treatments (overview)

Structure of a serial production plant

  • Handling
  • Oven
  • Press
  • Interface analysis
  • Sequences in-between the single components & their linking

Inline measurement

Structure of a press

  • Necessary equipment
  • Velocities
  • Forces

Cooling aggregates

T5-1 – Test tool

Micro hardness measurement

  • Air cooled part
  • Tool cooled part
  • Temperature variations

T6 – Simulation for hot forming

The unit aims at creating a comprehensive understanding of simulation as tool for supporting the hot forming process. The unit is not designed for simulation engineers but for forming engineers and technicians to get a better feeling of the importance of simulation as a tool to increase overall development efficiency for a product.

Fundamentals

  • Influence parameters
  • Interaction of mechanical and thermal properties
  • Failure criteria

Outlook tool calculation

T6-1 – PHS Laboratory

A sample automotive part is manufactured... The whole process chain, is going to be explained, starting from the semi-finished sheet metal, through part heating, direct press hardening with included measurement systems towards product final inspection is shown.

Press hardening of a PHS-part

  • Temperature measurement during the forming process
  • Temperature measurement after the forming process

Validation of Hot spots

T7 – Follow-up Operations

Follow-up operations are normally the last finishing step in a standard press hardening process chain. This part focuses on the part measurements in terms of quality control and the differences in trimming operations with high- and ultra-high strength steels to normal steels.

Trimming

  • Laser trimming
  • Hard trimming

Part measurements

  • 3MA System

T8 – Summarization

  • Summary of the training
  • FAQ
  • Feedback

Date

June 08th – June 12th (not on June 11th) from 01:00pm to 05:00pm CET

Price

1490,- Euro/Attendee

 

REGISTRATION

System Requirements

  • Windows PC with sound card, Windows 7, 8.1 or 10
  • Mac OS X version 10.11, 10.12 or 10.13
  • Internet access via DSL / cable (bandwidth min. 256 Kbit/s, 512Kbit/s recommended)
  • Browser (Microsoft Internet Explorer 11 or higher, Windows Edge, Mozilla Firefox, Google Chrome, Apple Safari)
  • Adobe Flash Player (current version)
  • Speaker or headset

Description

Introduction to new generation steels and aluminum alloys are also a part of this training.

This training serves as a basis for secondary modules:

  • Material card generation for finite element software (BMF402dg2)
  • Batch-to-batch variation of sheet metal properties (BMF408dg3)

Audience

Engineers, technicians and foremen in the fields of tooling, production, quality assurance, assembly and process planning. Anyone related to sheet metal forming.

Benefits

This training aims to bring all the professionals to speak the same langauge and be aware of the international or continental (EU or NAFTA) standards.

Methods

digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players in the PHS-market.

Content

The main focus of this training is the following key aspects and their sub items.

1. Definitions of sheet metals,
2. Sheet metal performance criteria,

3. Sheet metal tests:

    • Tensile test in detail
    • Hardness tests – conversion to tensile properties,
    • Bulge test,
    • FLC generation
    • VDA bending test.

4.How sheet metals are produced: alloying, hot rolling, pickling, oiling, cold rolling, etc.
5. Sheet metal types:

  • Draw quality steels
  • High strength steels
  • Advanced high strength steels
  • 2nd and 3rd generation AHSS
  • Aluminum alloys
  • Magnesium alloys

6. Coatings: EG, GI, GA, AS, ZM

Summarization

  • Summary of the training
  • FAQ
  • Feedback

Date

ON REQUEST

Price

790,- Euro/Attendee

 

REGISTRATION

System Requirements

  • Windows PC with sound card, Windows 7, 8.1 or 10
  • Mac OS X version 10.11, 10.12 or 10.13
  • Internet access via DSL / cable (bandwidth min. 256 Kbit/s, 512Kbit/s recommended)
  • Browser (Microsoft Internet Explorer 11 or higher, Windows Edge, Mozilla Firefox, Google Chrome, Apple Safari)
  • Adobe Flash Player (current version)
  • Speaker or headset

Level 2 - ADVANCED TRAINING (Online)

Description

The steel microstructure defines the final mechanical properties of the formed parts. The evolution of the microstructure characteristics, such as phase composition and grain size will be defined in theoretical units. The attendee will have an opportunity to create experimental investigations on the influence of various process parameters, for example, heating temperature, transfer time, and the cooling rate on the resulting mechanical properties. Furthermore, the influence of the process chain on the surface properties regarding coated and uncoated materials will be clearly represented. The structure and composition of the surface layers of press hardened materials will be investigated and analysed. The scheduled material investigations and analysis will be built on widely used press hardenable materials such as 22MnB5 and 34MnB5.
This course combines theoretical explanation of materials phenomena and final analytical examination of generated press hardened parts.

Audience

Engineers and technicians in the fields of production, tooling, material testing and QM & QS.

Benefits

This Advanced Training is aimed at the development of deepening each participant’s present knowledge in material behaviour during the complete press hardening process. This knowledge creates a solid foundation in understanding the influence of the process parameters on the press hardened components.

Methods

To achieve the objectives listed in the content, digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key-players in this market.

Content

Theoretical units aim at creating a deep understanding of material transformations during heating, cooling and forming.

T1: Introduction

  • Light weight design with steel
  • Press hardening process

T2: Steel structure and properties

  • Crystal structure
  • Phases in steel
  • Influence of time, temperature and alloying elements on phase composition
  • Phase diagrams: equilibrium, time-temperature-austenitisation (TTA), time-temperature-transformation (TTT), continuous-cooling-transformation (CCT)

T3: Basic properties of press hardenable steels

  • Chemical composition and mechanical properties
  • TTA, TTT and CCT diagrams
  • Coatings

T4: Phase transformations during press hardening and mechanical properties

  • Austenitisation
  • Formation of martensite, bainite and ferrite
  • Adjusting of mechanical properties

T5: Surface properties

  • Scaling of uncoated materials
  • Evolution of AlSI-coating
  • Surface roughness in dependence from the heating rate

T6: Materials Characterization

  • Destructive and non-destructive material testing
  • Tensile and hardness testing
  • Metallography, optical and laser microscopy
  • Scanning electron microscopy

T7: Summarization

  • Summary of the training
  • FAQ
  • Feedback

Date

June 15th – June 19th (not on June 18th) from 01:00pm to 05:00pm CET

Price

990,- Euro/Attendee

REGISTRATION

System Requirements

  • Windows PC with sound card, Windows 7, 8.1 or 10
  • Mac OS X version 10.11, 10.12 or 10.13
  • Internet access via DSL / cable (bandwidth min. 256 Kbit/s, 512Kbit/s recommended)
  • Browser (Microsoft Internet Explorer 11 or higher, Windows Edge, Mozilla Firefox, Google Chrome, Apple Safari)
  • Adobe Flash Player (current version)
  • Speaker or headset

Description

Nowadays energy efficiency and crash performance bring a lot of requirements within the material or the material selection. Anyone who wants to successfully manage automotive lightweight construction today must understand the principles of tailored part properties. Therefore, essential knowledge is crucial. The TPP training will give the participants the opportunity to take over a leading role in utilizing this technology on a theoretical level according to OEMs standards.

Audience

Engineers and technicians in the fields of production, material testing and QM & QS.

Benefits

Leading engineers in the field of press hardening with the key aspect on TTP will introduce new engineers and technicians into the comprehensive field of TTP. The participants will experience the different challenges in this field as well different design concepts by detecting the problems outlined in previous tests. Leading engineers in the field of press hardening with the key aspect on TTP will introduce new engineers and technicians into the comprehensive field of TTP. The participants will experience the different challenges in this field as well different design concepts by detecting the problems outlined in previous tests.

Methods

digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players in the PHS-market.

Content

Theoretical units aim at creating a deep understanding of TWB- and TRB- material transformations during heating, cooling and forming.

T1: The following questions will be answered

  • How can tailored part properties be achieved?
  • What are the advantages for locally different material properties regarding safety, weight and costs?
  • What needs to be considered for the PH process when working with TWB/TRB?
  • What are the possibilities to produce partial heat treated or tempered stamping parts?
  • How does tailored parts influence the tool design?
  • How and where can it be used in serial production?

T2: Summarization

  • Summary of the training
  • FAQ
  • Feedback

Date

ON REQUEST

Price

990,- Euro/Attendee

REGISTRATION

System Requirements

  • Windows PC with sound card, Windows 7, 8.1 or 10
  • Mac OS X version 10.11, 10.12 or 10.13
  • Internet access via DSL / cable (bandwidth min. 256 Kbit/s, 512Kbit/s recommended)
  • Browser (Microsoft Internet Explorer 11 or higher, Windows Edge, Mozilla Firefox, Google Chrome, Apple Safari)
  • Adobe Flash Player (current version)
  • Speaker or headset

Description

Most companies utilize finite element software for part design/performance, crash or formability analyses. It is very common to use the material cards from the built-in library or receiving data (material card) from other companies.

 *** Note: It is essential to have a spreadsheet editor (MS Excel or similar) to attend this training.

Audience

FE simulation engineers, material characterization engineers, design engineers.

Benefits

This training aims to introduce the physical meanings of most common material data, how to derive them experimentally and how to analyze them and put into the software.

Methods

digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players in the PHS-market.

Content

The main focus of this training is the following key aspects and their sub items.

  1. Definitions of material data required
  2. Analysis of a tensile test, determination of:
    • Elongation values,
    • Yield and tensile strengths,
    • n and r values based on ISO standards,
    • Elastic and «unloading» moduli
    • Bauschinger and Yoshida models

3. How to improve a flow stress data

    • Extrapolation methods
    • Other experiments

4. Forming limit curve:

  • Theory
  • How to determine an FLC based on ISO 12004 – 1 example analysis
  • How to estimate FLC based on data available

5. Yield Locus

    • Physical meaning and its effects,
    • von Mises, Hill, Corus-Vegter and Vegter Lite models
    • Methods of building a yield locus

6. Common material card file types

  • How to edit a material card
  • How to create a new one

Summarization

  • Summary of the training
  • FAQ
  • Feedback

Date

ON REQUEST

Price

990,- Euro/Attendee

REGISTRATION

System Requirements

  • Windows PC with sound card, Windows 7, 8.1 or 10
  • Mac OS X version 10.11, 10.12 or 10.13
  • Internet access via DSL / cable (bandwidth min. 256 Kbit/s, 512Kbit/s recommended)
  • Browser (Microsoft Internet Explorer 11 or higher, Windows Edge, Mozilla Firefox, Google Chrome, Apple Safari)
  • Adobe Flash Player (current version)
  • Speaker or headset

Description

Sheet metals are ordered by a material number or steel name, designated in several different standards. Most grades have very wide mechanical tolerances. When a new coil is received, it is very common to see problems in a press shop.

Audience

Process and die designers, component designers, press-shop managers.

Benefits

The targets of this training include: understanding all the terms in steel standards, identifying the correct standards, understanding the material variation limits and generating data for designing die and process for acceptable material variation.

Methods

digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players in the PHS-market.

Content

The main focus of this training is the following key aspects and their sub items.

  1. Mechanical characterization tests, physical meanings of the terms in steel standards.
  2. Sheet metal types: draw quality, high strength steels (HSS), advanced HSS (1st, 2nd and 3rd generations), stainless steels.
  3. Sheet metal standards: EN, VDA and OEM standards.
  4. Hands-on calculating material parameters over real tensile test data (yield, tensile, n and r-values).
  5. “Equivalent material” calculations over sample mill certificates and experiment data.
  6. Investigating and material cards in simulation programs.
  7. Generating “worst possible” material cards.
  8. Specifying acceptable variation of mechanical properties.

Summarization

  • Summary of the training
  • FAQ
  • Feedback

Date

ON REQUEST

Price

990,- Euro/Attendee

REGISTRATION

System Requirements

  • Windows PC with sound card, Windows 7, 8.1 or 10
  • Mac OS X version 10.11, 10.12 or 10.13
  • Internet access via DSL / cable (bandwidth min. 256 Kbit/s, 512Kbit/s recommended)
  • Browser (Microsoft Internet Explorer 11 or higher, Windows Edge, Mozilla Firefox, Google Chrome, Apple Safari)
  • Adobe Flash Player (current version)
  • Speaker or headset

Level 3 - EXPERT TRAINING (Online)

Description

The trainee gets the basic understanding on various effects of adjustments of the process parameters on relevant material processing properties.

Audience

This training is aimed at groups of people responsible for operating the running PHS production line.

Benefits

The participants will be sensitized to recognize and evaluate relevant product-quality indicators during the process and, therefore, to take proper decisions during PHS line operation.

Methods

digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players in the PHS-market.

Content

The focus of this training is the key process parameters and controls. The aim of this course is to provide the participant with basic knowledge about which relevant process parameters have an influence on component quality, process stability and thus enable him/her to achieve a safe and stable process as quickly as possible and to be able to react quickly and specifically to process disturbances.

  • Tool Life
  • Stable tool functions
  • Roller Pollution

as well as

  • Final Product properties
    • Surface properties
    • Coating consistency
    • Mechanical properties
    • Geometrical properties, etc.

Date

ON REQUEST

Price

390,- Euro/Attendee

REGISTRATION

System Requirements

  • Windows PC with sound card, Windows 7, 8.1 or 10
  • Mac OS X version 10.11, 10.12 or 10.13
  • Internet access via DSL / cable (bandwidth min. 256 Kbit/s, 512Kbit/s recommended)
  • Browser (Microsoft Internet Explorer 11 or higher, Windows Edge, Mozilla Firefox, Google Chrome, Apple Safari)
  • Adobe Flash Player (current version)
  • Speaker or headset

Beschreibung

Es werden grundlegende Kenntnisse über die vielfältigen Aspekte und Auswirkungen der Einstellungen von Prozessparametern auf relevante Materialverarbeitungseigenschaften vermittelt.

Teilnehmer

Diese Schulung richtet sich an Personengruppen, die für die Bedienung der laufenden PHS-Produktionslinie verantwortlich sind.

Ihr Nutzen

Die Teilnehmer werden darin sensibilisiert, relevante Produktqualitätsindikatoren während des Presshärteprozesses zu erkennen und zu bewerten und somit die richtigen Entscheidungen während des Betriebs der PHS-Linie zu treffen.

Methodik

Die digicon Academy bietet eine gezielte, praxis- und wirtschaftlich orientierte Wissensvermittlung in Form von Seminarvorträgen und Feldtests an Proben. Die beteiligten Trainer sind hochqualifizierte und erfahrene Schlüsselpersonen.

Inhalt

Der Schwerpunkt dieser Schulung liegt auf den wichtigsten Prozessparametern und Kontrollen. Das Ziel dieses Kurses ist es, dem Teilnehmer Basiswissen darüber zu vermitteln, welche relevanten Prozessparameter Einfluss auf Bauteilqualität und Prozessstabilität haben und ihn somit befähigen, schnellstmöglich zu einem sicheren und stabilen Prozess zu gelangen sowie auf Prozessstörungen kurzfristig und gezielt reagieren zu können.

  • Werkzeugstandzeit
  • Stabile Werkzeugfunktionen
  • Walzenverschmutzung

sowie

  • Endprodukteigenschaften
    • Oberflächeneigenschaften
    • Beschichtungskonsistenz
    • Mechanische Eigenschaften
    • Geometrische Eigenschaften etc.

Datum

ON REQUEST

Preis

390,- Euro/Teilnehmer

REGISTRATION

System Requirements

  • Windows PC with sound card, Windows 7, 8.1 or 10
  • Mac OS X version 10.11, 10.12 or 10.13
  • Internet access via DSL / cable (bandwidth min. 256 Kbit/s, 512Kbit/s recommended)
  • Browser (Microsoft Internet Explorer 11 or higher, Windows Edge, Mozilla Firefox, Google Chrome, Apple Safari)
  • Adobe Flash Player (current version)
  • Speaker or headset

Description

This specific training in the field of Press Hardening Technology (PHT) is based on the recent developments. This “update training” has been developed in cooperation with leading engineers and technicians. While it is an update training, it still keeps the total picture of PHT.

The aim of this training is to introduce engineers and technicians to the state of the art and how these could be translated into new opportunities for the team.

We discuss different opportunities as well as challenges that could occur during this relatively new PHS-processes, as well as their approach and methods of resolution.

The seminar is completed by real case studies of digicon Academy and its partners.

Audience

Engineers, technicians and foremen in the fields of tooling, production, quality assurance, assembly and process planning.

Prerequisites

Understanding the PHS-Process and experience in PHT.

Benefits

The participant will be required to think outside the box and think about new ways to rise efficiency which the company benefits from. Attendees get essential market updates and a comprehensive know-how upgrade.

Methods

digicon Academy provides a focused, practically and economically oriented knowledge transfer in form of seminar lectures. The involved trainer is highly qualified and an experienced key player in the PHS-market.

Content

The main focus of this training is to give the audience a total overview of the following key aspects and their sub items.

T1: Brief introduction and fundamentals in Press Hardening of Steel (PHS)

T2: Recent developments* in Press Hardening Technology (PHT)

  1. New uses by the OEM's
  • Passenger cars,
  • EV's, hybrids,
  • Light commercial vehicles,
  • Heavy commercial vehicles**
  1. New materials offered by the steelmakers
  • Servo press formable air harden able grades**
  • Available and new Zn coatings,
  • Al-Si Pro coating**
  • 2nd and 3rd generation PHS grades
    1.   -- 1.0 - 1.2 GPa grades,
    2.   -- >1.8 GPa grades,
    3.   -- ~1.5 GPa high elongation grades**
  1. Recent applications of tailored parts:
  • Part consolidation through TWB and soft zones
  • Part performance improvement
  • Potential of new grades with TWB’s**
  1. New process methods
  • Servo press forming**
  • Reducing laser trimming
  • New furnaces: walking beam furnace

5. Quality control and maintaining a line

  • 3MA nondestructive testing
  • -- Furnace maintenance: new roller with increased build-up resistance

 * recent developments mostly focus on technologies that have been used since 2015

** items marked are only available since 2018

T3: Summarization

  • Summary of the training
  • FAQ
  • Feedback

Date

ON REQUEST

Price

790,- Euro/Attendee

REGISTRATION

System Requirements

  • Windows PC with sound card, Windows 7, 8.1 or 10
  • Mac OS X version 10.11, 10.12 or 10.13
  • Internet access via DSL / cable (bandwidth min. 256 Kbit/s, 512Kbit/s recommended)
  • Browser (Microsoft Internet Explorer 11 or higher, Windows Edge, Mozilla Firefox, Google Chrome, Apple Safari)
  • Adobe Flash Player (current version)
  • Speaker or headset