Sheet forming simulation for AHSS components in the automotive industry

The trend in the automotive industry towards new advanced high strength steels (AHSS), combined with the ongoing reduction in program lead times have increased the need to get tool designs right, first time. Despite the fact that the technology used by sheet metal stamping companies to design and manufacture tooling is advancing steadily, finding optimal process parameters and tool geometries remains a challenge. Consequently, there has been a transition from designs based largely on trial and error techniques and the experience of the stamping engineer, to the increased use of virtual manufacturing and finite element (FE) simulation predictions as an indispensable tool in the design process. This work investigates the accuracy of FE techniques in predicting the forming behavior of AHSS grades, such as TRIP and dual phase, as compared to more commonly used conventional steel grades. Three different methods of simulation, one-step, implicit and explicit techniques, were used to model the forming process for an automotive part. Results were correlated with experimental strain and thickness measurements of manufactured components from the production line.

Design of experiments and springback prediction for AHSS automotive components with complex geometry

With the drive towards implementing Advanced High Strength Steels (AHSS) in the automotive industry; stamping engineers need to quickly answer questions about forming these strong materials into elaborate shapes.
Commercially available codes have been successfully used to accurately predict formability, thickness and strains in complex parts. However, springback and twisting are still challenging subjects in numerical simulations of AHSS components. Design of Experiments (DOE) has been used in this paper to study the sensitivity of the implicit and explicit numerical results with respect to certain arrays ofuser input parameters in the forming ofan AHSS component. Numerical results were compared to experimental measurements of the parts stamped in an industrial production line. The forming predictions of the implicit and explicit codes were in good agreement with the experimental measurements for the conventional steel grade, while lower accuracies were observed for the springback predictions. The forming
predictions of the complex component with an AHSS material were also in good correlation with the respective experimental measurements. However, much lower accuracies were observed in its springback predictions. The number of integration points through the thickness and tool offset were found to be of significant importance, while coefficient of friction and Young's modulus (modeling input parameters) have no significant effect on the accuracy of the predictions for the complex geometry.

Modelling of tooling wear in trim dies for AHSS

Using Advanced High Strength Steels (AHSS) in forming and cutting dies generates higher loads in tools. Tool wear is an issue when applying AHSS. This study investigates the effect of process parameters such as clearance, material properties and punch/die bluntness on contact pressure values and tool wear. Some desirable process parameters that minimise wear have been found.

Fatigue characterisation of HSS and AHSS

The thesis investigated the fatigue behaviour of modern automotive steels, which are stronger and more ductile than traditional steels. The failure mechanisms of these steels under fatigue were identified, enabling researchers to further improve the material properties, which will ultimately lead to a reduction in overall vehicle mass.

Wear mechanisms in forming of HSS and AHSS

Code : C/64/09

Properties and automotive applications of advanced high-strength steels (AHSS)

Advanced high-strength steels (AHSS) are a class of steel used primarily in sheet form for automotive structures. The microstructures of the types of steel in this classification were initially multiphase, with ferrite as the dominant phase; however, grades introduced more recently have been fully martensitic or based on austenite. This chapter initially introduces the requirements of an automotive body structure, then the different classes of AHSS that have been used in the automotive industry and their typical characteristic tensile properties. The specific properties that are required for steel used in automotive body structures are subsequently described, including formability and crash behaviour. Finally, some of the current and future trends in the development of new steel grades are discussed.

Effect of susceptibility to interfacial fracture on fatigue properties of spot-welded high strength sheet steel

While advanced high strength steels (AHSS) have numerous advantages for the automotive industry, they can be susceptible to interfacial fracture when spot-welded. In this study, the susceptibility of interfacial fracture to spot-weld microstructure and hardness is examined, as well as the corresponding relationships between fatigue, overload performance, and interfacial fracture for a TRIP (transformation induced plasticity) steel. Simple post-weld heat-treatments were used to alter the weld microstructure. The effect on interfacial fracture of diluting the weld pool by welding the TRIP material to non-TRIP steel was examined, along with the effect of altering the base material microstructure. Results show that weld hardness is not a good indicator of either the susceptibility to interfacial fracture, or the strength of the joint, and that interfacial fracture does not necessarily lead to a decrease in strength compared to conventional weld-failure mechanisms, i.e. button pullout. It was also found that while interfacial fracture does affect low cycle to failure behavior, there was no effect on high cycle fatigue.

Influence of low-strain deformation characteristics of high strength sheet steel on curl and springback in bend-under-tension tests

The influence of low-strain deformation behavior on curl and springback in advanced high strength steels (AHSS) was assessed using a bend-under-tension test. The effect of yielding behavior on curl and springback was examined by heat-treating two dual-phase steels to induce yield point elongation, while keeping a relatively constant tensile strength and a constant sheet thickness. A dual-phase and TRIP steel with similar initial thickness and tensile strengths were also examined to investigate the effect of work-hardening on curl and springback. It is shown that while current understanding limits prediction of curl and springback in bending under tension using only the initial sheet thickness and tensile strength, both the yielding and work-hardening behavior can affect the results. Explanations for these effects are proposed in terms of the discontinuous yielding and flow stress in the materials.

Multiscale particle-in-cell modelling for advanced high strength steels

Advanced High Strength Steels (AHSS) offer outstanding characteristics for efficient and economic use of steel. The unique features of AHSS are direct result of careful heat treatment that creates martensite in the steel microstructure. Martensite and carbon content in the microstructure greatly affects the mechanical properties of AHSS, underlining more importance on microstructural discontinuities and their multiphase characteristics. In this paper, we present the Multiscale Particle-In-Cell (MPIC) method for microstructural modelling of AHSS. A specific particle method [1] usually used in fluid mechanics is adapted and implemented in a parallel multiscale framework. This multiscale method is based on homogenisation theories; with Particle-In-Cell (PIC) method in both micro and macroscale, and offers several advantages in comparison to finite element (FE) based formulation. Application of this method to a benchmark uniaxial tension test is presented and compared with conventional FE solutions.

Accuracy and precision assesment of stochastic simulation tools for springback variation

The sheet forming industry is plagued by inherent variations in its many input variables, making quality control and improvements a major hurdle. This is particularly poignant for Advanced High Strength Steels (AHSS), which exhibit a large degree of property variability. Current FE-based simulation packages are successful at predicting the manufacturability of a particular sheet metal components, however, due to their numerical deterministic nature are inherently unable to predict the performance of a real-life production process. Though they are now beginning to incorporate the stochastic nature of production in their codes. This work investigates the accuracy and precision of a current stochastic simulation package, AutoForm Sigma v4.1, by developing an experimental data set where all main sources of variation are captured through precise measurements and standard tensile tests. Using a Dual Phase 600Mpa grade steel a series of semi-cylindrical channels are formed at two Blank Holder Pressure levels where the response metric is the variation in springback determined by the flange angle. The process is replicated in AutoForm Sigma and an assessment of accuracy and precision of the predictions are performed. Results indicate a very good correspondence to the experimental trials, with mean springback response predicted to within 1 ° of the flange angle and the interquartile spread of results to within 0.22°.

Experimental and numerical evaluation of forming and fracture behaviour of high strength steel

Car manufacturers are under pressure to reduce vehicle mass while maintaining comfort and passenger safety for current and future vehicles. To meet this demand the steel industry has developed Advanced High Strength Steels (AHSS) that promise higher strength and improved formability compared to conventional steel grades. Even though significant research has already been performed to evaluate the material properties and forming behaviour of most AHSS types, only a limited literature is available on their necking and fracture behaviour and the effect on formability. This paper examines and compares the thinning, necking and fracture behaviour of two AHSS and one conventional steel type, namely TRIP, DP and HSLA. Uniaxial, plane and biaxial strain conditions are investigated by tensile, cup drawing and stretch forming tests and by using numerical methods. The test results indicate that significant differences exist in necking and fracture behaviour between all three steel types.

Microstructural analysis of pre-strained TRIP steel after fatigue testing

The widespread introduction of multiphase sheet steels in the automotive industry has led to considerable interest in the fatigue properties of these materials. The different microstructural phases within matelials such as TRIP steels can influence the fatigue behaviour due to the manner in which the cyclic strain is accommodated within these phases. In this study fully reversed straincontrolled fatigue tests were perfonnrmed on a commercially-produced uncoated TRIP 780 steel both in the as-received and 20 % prestrained condition. The pre-strained TRIP steel showed significant cyclic softening at higher strain amplitudes, whereas some initial work hardening was observed at lower strain amplitudes before cyclic softening. The cyclic stabilised strength of the pre-strained TRIP steel was independent of strain amplitude, while the cyclic stabilised strength of the as-received TRIP steel increased with strain amplitude. Transmission Electron Microscopy TEM was used to examine the effect of the cyclic deformation on the microstructure of the different conditions, with the differences in fatigue behaviour explained based on the differences in the deformation structure formed within the steel (i.e. dislocation density and sub-structure and microband formation).