AHSS FORMING SIMULATION FOR SHEAR

FRACTURE AND EDGE CRACKING

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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Automotive Sheet Steels

SF590

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AHSS Characteristics
(Advantages)

High tensile strength

High crash energy absorption
High dent resistance
Good combination of strength and formability
High stretch limit and durability (Stretch
flange high strength steel)

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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

Conventional formability evaluation

Edge cracking
Stretch bending at tight radius
Case studies

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Conventional Simulation
Prediction

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DP600 Panel Forming

Draw split

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DP780 Forming

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DP980 B-pillar Reinf

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Edge Stretch Cracking

Suspension Member

Edge Stretch in draw in plane

Stretch flanging out of plane

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Poor Correlation in
Predicting Edge Cracking

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Forming Limit Curve and

Hole Expansion Limit
Forming Limit Diagram

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

-50 -40 -30 -20 -10

10

Minor Strain %

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20

30

40

50

Simulation of Conical
Punch Hole Expansion

16

Expan D(mm)

15

Plot of strain mode along edge

Strain path along uniaxial tension

Inner D

14

Test

13
12
11
10
9
8
0

Punch (mm)

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10

Hole Expansion Test

(HER)

D f D0
D0

X 100

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Lowest HER
DP600
590Y - Conical

Hole Expansion Ratio

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

Lowest HER for limit in production environment

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20.7%

Case Study 1

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Major Strain Exceeds

Edge Stretch Limit

Principal Strain 24.5 %

DP600
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Case Study 2
DP780 Steel Flanging

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Scallop Pre-form

Max stretch is 22% which exceeds the edge

stretch limit
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Modify Pre-form

undeform locations for

stretch in flanging stage

deform locations in pre-form stage

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Modified Pre-form

No edge stretch
in pre-form
(Major strain =10.5%)

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No Pre-form

(Major strain =15.5%)

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Comparison of
Different Pre-forms

Major strain = 22%

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

Optimal Material Designed

for High Edge Stretch
Application

SF590 for stretch

greater than 100%

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Stretch Bending Fracture

DP980

DP980 Coil#: GE656163010

Severe cracking

DP780

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Poor Prediction
Correlation

DP780

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Stretch Bending Limit

Study for AHSS

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Stretch Bending Limit

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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

Hole Expansion (%)

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

M. F. Shi, X.M. Chen, Stretch Flange-ability Limits of

Advanced High Strength Steels, SAE Technical paper #
2007-01-1693
A. Konieczny and T. Henderson, On Formability
Limitations in Stamping Involving Sheared Edge
Stretching, SAE Technical paper # 2007-01-0340
M.S. Walp, A. Wurm, J.F. Siekirk, and A.K. Desai,
Shear Fracture in Advanced High Strength Steels,
SAE Technical paper # 2006-01-1433

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Questions & Comments

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