Ming Chen
United States Steel Corporation
D.J. Zhou
Chrysler LLC
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Outline
AHSS characteristics
Conventional formability evaluation
Edge cracking
Stretch bending at tight radius
Solutions
Tool/Process modifications
Optimized material selection
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SF590
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AHSS Characteristics
(Advantages)
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AHSS Characteristics
(Disadvantages)
Edge splitting
Stretch bending in tight radius
Springback
Tool wear & deflection
High press and binder force
Weldability
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Simulation
and Prediction
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Conventional Simulation
Prediction
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Draw split
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DP780 Forming
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Poor Correlation in
Predicting Edge Cracking
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160
FLD
140
Major Strain %
Deformation Mode at
stretch edge is Uniaxial
tension
Point A: Limit of ideal
edge condition
Point C: Limit in worse
condition
Tension
120
100
80
60
40
20
0
10
Minor Strain %
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20
30
40
50
Simulation of Conical
Punch Hole Expansion
16
Expan D(mm)
15
Inner D
14
Test
13
12
11
10
9
8
0
Punch (mm)
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10
(HER)
D f D0
D0
X 100
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Lowest HER
DP600
590Y - Conical
Burr
Burr
Upout
BurrDown
in
Burr
100.0%
80.0%
60.0%
40.0%
20.0%
0.0%
Ream
Laser
1.1%
6.4%
13.6%
Clearance
20.7%
Case Study 1
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DP600
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Case Study 2
DP780 Steel Flanging
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Scallop Pre-form
Modify Pre-form
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Modified Pre-form
No edge stretch
in pre-form
(Major strain =10.5%)
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No Pre-form
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Comparison of
Different Pre-forms
Modified pre-form
Major strain = 10%
No pre-form
Major strain = 15%
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Stretch Comparison of
Different Pre-forms
Edge Stretch Comparison
0.24
0.2
Major Strain
Scallop Pre-form
0.16
No Preform
Modi Preform
0.12
0.08
0.04
0
0
0.01
0.02
0.03
Time (ms)
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0.04
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DP980
DP780
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Poor Prediction
Correlation
DP780
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Material Improvement
Steel
YS
(MPa)
UTS
(MPa)
Total
Elongation (%)
Yield
Ratio
(5)
High Yield
0.086
744
1023
12.2
0.73
25
Low Yield
0.098
632
1011
14.2
0.63
18
Stress-Strain curves
True stress in MPa
1000
800
600
400
LY
LY
DP
200
0
0.00
HY
0.10
True strain
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0.20
0.30
Improved HER
AHSS Hole Expansion
35
Regular
LY
30
Process2
HY
25
20
15
10
5
0
0.0
1.6
Pre-strain (%)
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4.4
Improved Stretch
Bending
DP780HY
DP780LY
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Improved Local
Formability
DP980LY
DP980HY
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Summary
Conventional FLD is suitable for general
deformation mode only
Utilize appropriate hole expansion limit in the
simulation for edge stretch
Check major strain in stretching edges
Check R/T ratio in stretch bending
Optimal material selection based on specific
applications
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References
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