Institute of Ferrous Metallurgy

RWTH Aachen
Topic 11:
Formability of thin sheet

11.1 Steel grades

Introduction
Steels for car body applications
11.2 Test procedures
Deep drawing and stretch drawing
Strain analysis and damage curves

Prof. Dr.-Ing. Wolfgang Bleck

Outline

Principle sheet metal forming operations

11.1 Steel grades
Introduction
Steels for car body applications
11.2 Test procedures
Deep drawing and stretch drawing
Strain analysis and damage curves

Outline

The cold formability of a sheet is it`s ability to reach the final

shape of a certain hollow part or profile without any defect
under a given strain.
The success of a forming operation is not only determined by
the sheet material. The material, the forming tool and the press
machine constitute a close system with several intersection
areas.
The technological property cold formability reflects the plastic
behaviour of a steel during a press operation without external
heating; three phases can be distinguished:
Yielding - Strain hardening - Ductile failure.

- shearing
- bending
- stretching
- deep drawing
Possible failure mechanisms during forming
- fracture
- necking
- wrinkling
- dimensional inaccuracy
Principles of sheet metal forming

- Mechanical properties: YS, YS/TS-ratio, Au, A80

- Flow curve: = c*n
= 00 - (00 - y) * exp (- / 0)
= c*
- Strain hardening behaviour: n,d / d -analysis
- Anisotropy: rm, r
- Strain rate sensibility: m-value
- Forming Limit Diagram: FLD0, LDH, strain path
- Limiting Drawing Ratio: LDR
- Temperature Sensibility
- Grain size, phase distribution, r stability

Definitions

Material parameters for sheet metal forming

11.1 Steel grades

Introduction
Steels for car body applications
11.2 Test procedures
Deep drawing and stretch drawing
Strain analysis and damage curves

Outline

Steels for car body applications

3
1

3
1

3 = 0.577Y
1

II
3

V
1

III

- 1

+Y

1 = 23 = 1.155Y

VI
- 1

1 = 21

+Y

2 = 0

+Y

21+ 23 13 = Y2

-Y

2 = 0
Pure shear
1 = - 3

IV

+Y

1 = 0.577Y, 3= - 0.577Y

-Y

1
- 3

- 3

Maximum shear stress yield locus

Octahedral shear stress yield locus

y / k f
r=
5

1000
TRIP

r=
0

r=
1

IV

x/kf

True stress , MPa

r=
3

800
600

DP
IF-HS
FeP04

400

IF
200
x uniform elongation

0
III

II

Effect of the r-value on the yield locus

0,1

True strain

0,2

0,3

Flow curves of cold rolled sheet steels

x uniform elongation

1600

6000

Temperature:
Strain hardening , MPa

3000

1200

True stress , MPa

Strain hardening rate , MPa

4000

DP
2000
TRIP
1000

IF-HS
FeP04

0
0

0,1

True strain

IF

800

400

0,2

0,3

4000

2000

0
0

0,2

0,4

True strain

0,2

0,4

True strain

Effect of temperature on the strain hardening

of austenitic stainless steel 1.4571

Strain hardening of cold rolled sheet steels

60

Fe P05

FLD0

40

Major strain

ZStE 300
Al 5182

30

Increasing:
thickness
n-value
r-value
lubrication

20

10
thickness: 0,9 mm
0
-20

-10

10

20

30

40

Minor strain 2

50

Minor strain 2, %

Parameters influencing the forming limit curve

Forming limit curves of different sheet materials

ng

1= 2

11.1 Steel grades

Introduction
Steels for car body applications

hD
raw
i ng

i
aw
Dr

win
Dra
ple
Sim

ep
De

1 = ln (l1 / d)

2= 0

plane strain

1= -22

S tr
etc

1= - 2

Major strain 1

Major strain 1, %

50

2 = ln (l2 / d)

d
l2

11.2 Test procedures

Deep drawing and stretch drawing
Strain analysis and damage curves

l1
0
Minor strain 2

Effect of different stress state on sheet deformation

Outline

t
Deep Drawing

Stretch Drawing

1.

2.

crack
deformed
area

1. flange
2. wall

deformed
area

crack

3. bottom

3.
Stress states during deep drawing

Comparison of deep drawing and stretch drawing

n-value

r-value

Flow curve

nation

s
l
b

Result

2.4

15

2.3

Earning h/h, %

Determi-

Limiting drawing ratio LDR

Definition

2.2
2.1
2.0

10

0
0

0.5

1.0

1.5

2.0

0.3

2.5

0.4

Importance of r- and n- value for sheet forming

0.7

0.8

T
T

T
T

0.6

Effect of anisotropy parameters on drawability

t0

r0

0.5

Planar anisotropy r

Normal anisotropy rm

measuring point

rd

rd

D E F

ri
r0
1. punch
2. die
3. blank holder

Schematic representation of deep drawing

rc
rc

Schematic representation of hole expansion

0,6
scatter band mild steels
DP 500 non
temper rolled

R
Major strain 1

Rc

DP 500 temper rolled

0,4
Fe P04

Fe P04
0,2

SLR

DP 500 non
temper rolled
DP 500 temper rolled

Rc= hole radius

Rc

0,0
-0,4

-0,2

0,0

0,4

Strain distribution of the part door inner

for steels of different strength

Failure modes during hole expansion

11.2 Test procedures

Deep drawing and stretch drawing
Strain analysis and damage curves

0,2

Minor strain 2

R = punch radius

11.1 Steel grades

Introduction
Steels for car body applications

SLR = Strain limit ratio

target

press shop
design

material

component
strain
distribution

FLC
comparison
Z <=> G

analysis
Z << G

result

Z < G

okay, change
steel grade

conclusion

Z >- G

1. change
forming
operation

okay

2. change steel
grade
3. change design

Outline

Procedure during strain analysis

Tearing
Fracture
Fracture

Sa
fe

Wrinkling
Compression

fo
rm
in
g

re

gi
on

2
Damage

-2
1

Measuring grid on a Nakazima sample

for FLC determination

Various forming limits during sheet forming

The NADDRG (North American Deep Drawing Research

Group) has developed a simple method for constructing the
FLC from 2 parameters.
1. FLD0 (1 at 2 = 0) is calculated by
FLD0 = (23.3 + 360 t) / (n / 0.21)
where t = thickness in inch, n = n-value.
2. The left hand part of the FLC is given bei a straight line
starting at FLD0 with the slope -1.
3. The right hand part of the FLC is calculated by
1 = (1- 2/1) * n
Ductile crack initiation

NADDRG recommendation for FLC

1000

Average length of
Inclusion : 2,45 m
Strutural steel

Number of oxides / cm2

800

Damage curve Hancock and Mackenzie

p

v,i = exp -

3
2

m
v

600

Gurson Modell:

400

200

Average length of
inclusion: 4,50 m

20

40

60

80

Dependency of oxide number on the total

oxygen content

Tension test

2 f cosh

kk
- (1 + f 2) = 0
2 m

Rousselier Modell:

Content of oygen, ppm

Metallography

eq
m
F = + D 1 f exp - R (p)
1

IF - Steel

v 2
+
m

Modelling the ductile failure behaviour

FE- calculation

S 460 M F/B/P
S 460 M B/M
S 460 M M ann.
S 460 M M
S 460 M F/P
IF (G = 3,7)
IF (G = 5,4)

comparison

Equivalent strain pv

IF
1,5

1
S 460 M F/B/P
1,5

Global strain at inition

S 460 M M ann.
0

Local strain and stress state at

crack initiation

Determination of damage curves

0,3

0,6

0,9

1,2

1,5

1,8

2,1

Stress triaxiality m / v

Damage curves of different steels

and microstructures

Equivalent strain pv

IF
1,5

effect of strength
S 460 M F/B/P

effect of cleanliness

1,5
S 460 M M ann.
0

0,3

0,6

0,9

1,2

1,5

1,8

2,1

Stress triaxiality m / v

Effects on the damage curve