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°.

Multiphase material modelling by multiscale particle-in-cell method

A particle-based method for multiscale modeling of multiphase materials such as Dual Phase (DP) and Transformation Induced Plasticity (TRIP) steels has been developed. The multiscale Particle-In-Cell (PIC) method benefits from the many advantages of the FEM and mesh-free methods, and to bridge the micro and macro scales through homogenization. The conventional mesh-based modeling methods fail to give reasonable and accurate predictions for materials with complex microstructures. Alternatively in the multiscale PIC method, the Lagrangian particles moving in an Eulerian grid represent the material deformation at both the micro and macro scales. The uniaxial tension test of two phase and three-phase materials was simulated and compared with FE based simulations. The predictions using multiscale PIC method showed that accuracy of field variables could be improved by up to 7%. This can lead to more accurate forming and springback predictions for materials with important multiphase microstructural effects.

Mechanochemical synthesis of nanoparticulate ZnO–ZnWO4 powders and their photocatalytic activity

In this study, mechanochemical reaction systems with H₂WO₄ as a precursor were investigated for the synthesis of nanoparticulate powders of WO₃, ZnWO₄, and dual-phase (ZnWO₄)_x(ZnO)_1–x. The objective was to establish whether mechanochemical processing can be used to manufacture high activity photocatalysts in the ZnO–WO₃ system. Milling and heat treatment of H₂WO₄ + 12NaCl was found to result in the formation of irregularly shaped platelets of a sodium tungstate rather than nanoparticles of WO₃. Powders of single-phase ZnWO₄ and dual-phase (ZnWO₄)_x(ZnO)_1–x were successfully synthesised by incorporating H₂WO₄ into the ZnCl₂ + Na₂CO₃ + 4NaCl reactant mixture. The photocatalytic activity of these powders was evaluated using the spin-trapping technique with electron paramagnetic resonance spectroscopy. It was found that the photocatalytic activity decreased with the ZnWO₄ content. This decrease in activity was attributed to the larger average particle size of the ZnWO₄ component compared to the ZnO, which reduced the surface area available for interfacial transfer of the photogenerated charge carriers.

Cyclic deformation of advanced high-strength steels : mechanical behavior and microstructural analysis

The fatigue properties of multiphase steels are an important consideration in the automotive industry. The different microstructural phases present in these steels can influence the strain life and cyclic stabilized strength of the material due to the way in which these phases accommodate the applied cyclic strain. Fully reversed strain-controlled low-cycle fatigue tests have been used to determine the mechanical fatigue performance of a dual-phase (DP) 590 and transformation-induced plasticity (TRIP) 780 steel, with transmission electron microscopy (TEM) used to examine the deformed microstructures. It is shown that the higher strain life and cyclic stabilized strength of the TRIP steel can be attributed to an increased yield strength. Despite the presence of significant levels of retained austenite in the TRIP steel, both steels exhibited similar cyclic softening behavior at a range of strain amplitudes due to comparable ferrite volume fractions and yielding characteristics. Both steels formed low-energy dislocation structures in the ferrite during cyclic straining.

Effect of bake-hardening on the structure-property relationship of multiphase steels for the automotive industry

The effect of a bake-hardening (BH) treatment on the microstructure and mechanical properties has been studied in C-Mn-Si TRansformation Induced Plasticity (TRIP) and Dual Phase (DP) steels after: (i) thermomechanical processing (TMP) and (ii) intercritical annealing (IA). The steels were characterized using X-ray diffraction, transmission electron microscopy (TEM) and three-dimensional atom probe tomography (APT). All steels showed high BH response. however, the DP and trip steels after IA/BH showed the appearance of upper and lower yield points, while the stress-strain behavior of the trip steel after TMP/BH was still continuous. This was due to the higher volume fraction of bainite and more stable retained austenite in the TMP/BH steel, the formation of plastic deformation zones with high dislocation density around the "as-quenched” martensite and “TRIP” martensite in the IA/BH DP steel and IA/BH TRIP steel, respectively.

Experimental evaluation of curl and tensile properties of advanced high strength sheet steels

The response of HSLA steel, 590R, and dual-phase steel, DP-600, to non-uniform deformation imposed in a laboratory Bending-Under-Tension (BUT) test apparatus was evaluated. Samples were deformed with both low and high back tension forces at bend angles of 45 and 90 degrees, and evaluated to determine the ""side-wall curl,"" i.e., the curvature in the sheet section in contact with the die. The results indicate that there are no consistent differences between the two steels, 590R and DP-600. It was found that back tension, tensile strength and sheet thickness were the primary factors affecting curl. The bend angle has an influence on curl, with the curl radius at a 90ø bend angle being greater than the curl radius at a 45\mD bend angle.

Multi-scale modelling of DP590 steel

Dual Phase (DP) steel one of the Advanced High Strength Steels (AHSS) has a two phase microstructure where soft and hard phase acts together to offer a high strength composite effect. The high strength, however, must be balanced with ductility so that complex parts and designs can be manufactured from AHSS sheets. However, during forming certain grades of DP steel a sudden crack can occur without any intimation of necking. Thus, due to this abnormal forming behaviour, is difficult to accurately predict because most classical modelling approaches are not designed for such micro-structurally heterogeneous materials. These modelling approaches are generally based on an average representation of the material behaviour in a continuum mechanics formulation. This works for materials that are homogenous, or at least could be assumed to be homogenous at scales lower than the naked eye can see. However, for a material like AHSS, the microstructure plays a significant role in dictating the mechanical behaviour at the macro-scale. This paper studies the multi-scale modelling ofDP590 steel. It is found that the sufficient accuracy can be achieved from multi-scale modelling while comparing with the experiments.

Conducting composite using an immiscible polymer blend matrix

Carbon black (CB) fillers were used to study the feasibility of achieving multiple percolation using an immiscible (polar) polymer blend matrix. By tailoring the morphology of the insulating dual phase matrix it has been shown that the percolation threshold (Ф_c) can be reduced over single-phase matrices. Cocontinuity in the polymer matrix is important in reducing Ф_c by either preferentially isolating the conducting filler at the interface of the two phases or within one particular continuous phase of the matrix thereby forming a continuous conducting network within a continuous network (multiple percolation). Actual melt processing time has been found to influence the dispersion of the fillers and hence Ф_c. Polarity of the matrix as well as the processing method has also been found to influence the dispersion of the filler within the host polymer.

Effect of manufacturing process on the final properties of advanced high strength steels for automotive applications

The performance of multiphase steels with high strength and improved toughness or ductility, such as intercritically annealed dual-phase (DP) and transformation-induced plasticity (TRIP) steels, is of key importance to the automotive industry. In this work we have considered the entire manufacturing process and the effects of this on the final product performance. These steels are formed to produce the required final shape and then the car is paint baked. In this work we also consider the effect of cold working and bake hardening on the fatigue life of the components.

Fracture of DP590 steel : a multi-scale modeling approach

Advanced high strength steel sheets are one of the higher strength advance material developed by the steel industry for automotive bodies. One of the categories of this advanced high strength steel is Dual Phase (DP) steel. This steel consists of a two phase microstructure where soft and hard phase acts together to offer a high strength composite effect. The combination of high strength and ductility exhibited by these sheets allows the design and manufacture of complex parts. However, during forming certain grades of DP steel sudden cracking can occur without any intimation of necking. This abnormal forming behavior is difficult to accurately predict because most classical modelling approaches are not designed for such micro-structurally heterogeneous materials. These modelling approaches are generally based on an average representation of the material behaviour in a continuum mechanics formulation. This works for materials that are homogenous, or at least could be assumed to be homogenous at scales lower than the naked eye can see. However, for a material like advanced high strength steel, the microstructure plays a significant role in dictating the mechanical behavior at the macro-scale. This paper studies the forming and fracture behavior through multi-scale modeling of DPO590 steel. It is found that the sufficient accuracy can be achieved from multi-scale modeling when comparing with experiments.

Springback data from stamping and simulating the forming of advanced high strength steel

This dataset is comprised of a spreadsheet of simulation result files, cross-section geometries of stamped parts, strain results of cross-section of stamped parts, simulation data (strain stress displacement energies), and variation data of material properties of a single coil. This data is a collection of both experimental and simulation results from industrial and laboratory stamping of advanced high strength steels (AHSS). The steels that were stamped were a typical high-strength low-alloy (HSLA) steel, a transformation-induced plasticity (TRIP) steel, a super HSLA steel, and a dual phase (DP) steel. The selected part was an automatic Ford Falcon front cross-member component using the Ford Geelong stamping plant. The variation of the material and stamped parts was also collected.

Microstructure-property relationship of the high strength low alloy steels during tensile testing at high strain rates

Positive The influence of strain-rate on the room temperature mechanical properties of the Dual-Phase and Transformation Induced Plasticity (TRIP) steels was investigated.The results showed that both the plastic strain, and strength properties increased with increasing strain rates at high strain rates.At strain rates lower than approximateil 1s ~ (-1) the properties no longer have an advantageous proportionality to strain rate and remain strain rate neutral.Possible explanations are offered for trends exhibited, in terms of thermal and athermal considerations, in relation to the respective microstructures of the two steels

Strain hardening behavior of high performance FBDP, TRIP and TWIP steels

Based on n-value differential equation and microstructural observation, strain hardening behaviors of FBDP, TRIP, and TWIP steels during uniaxial tension were investigated. TRIP steel exhibits both superior strength and ductility than FBDP steel, and TWIP steel displays much higher total and uniform elongations in comparison to FBDP and TRIP steels. The instantaneous n values of FBDP and TRIP steels increase at small strains, reach a maximum value, smoothly decrease at higher strains, and then rapidly drop up to the specimen rupture. The strain hardening of TRIP steel persists at higher strains where that of FBDP steel begins to diminish. TWIP steel exhibits gradually increased instantaneous n values over the whole uniform plastic deformation, implying that TWIP steel shows a much larger strain hardening capability than FBDP and TRIP steels.

Using the solid-shell element to model the roll forming of large radii profiles

Roll forming is an incremental bending process for forming metal sheet, strip or coiled stock. Although Finite Element Analysis (FEA) is a standard tool for metal forming simulation, it is only now being increasingly used for the analysis of the roll forming process. This is because of the excessive computational time due to the long strip length and the multiple numbers of stands that have to be modelled. Typically a single solid element is used through the thickness of the sheet for roll forming simulations. Recent investigations have shown that residual stresses introduced during steel processing may affect the roll forming process and therefore need to be included in roll forming simulations. These residual stresses vary in intensity through the thickness and this cannot be accounted for by using only one solid element through the material thickness, in this work a solid-shell element with an arbitrary number of integration points has been used to simulate the roll forming process. The system modelled is that of roll forming a V-channel with dual phase DP780 sheet steel. In addition, the influence of other modelling parameters, such as friction, on CPU time is further investigated. The numerical results are compared to experimental data and a good correlation has been observed. Additionally the numerical results show that the CPU time is reduced in the model without friction and that considering friction does not have a significant effect on springback prediction in the numerical analysis of the roll forming process.