Fracture toughness to assess the effect of trimming on the fatigue behaviour of high-strength steels for chassis parts

High-strength steels are widely used in vehicle body-in-white, offering a good balance between crashworthiness and lightweight design. The increased requirements of heavier electric vehicles, in terms of fatigue resistance and crashworthiness, highlight that chassis parts have remarkable lightweighting potential. However, applying these grades in chassis parts is not straightforward, as the forming processes, like trimming, may introduce surface defects that compromise the fatigue resistance of the component. This work presents a material selection strategy for the applicability of high-strength steels in chassis parts of electric vehicles. The proposed approach allows the evaluation of the key parameters of the chassis parts in a simple way. The crash performance is evaluated through fracture toughness using the essential work of fracture (EWF) methodology. The method is applied to thin high-strength steel sheets employing double-edge notched tensile specimens (DENT). On the other hand, fatigue performance is investigated in terms of fatigue resistance for both notched and unnotched specimens. The results for different complex-phase and dual-phase steels show a good agreement between the EWF and the fatigue notch factor. The method could help apply high-strength steel to chassis parts, as designers will have a tool to focus the expensive fatigue tests on the best material candidates.Postprint (published version

Fatigue resistance evaluation of high Mn-TWIP steel through damage mechanics: A new method based on stiffness evolution

The work presented here deals with the implementation of a new methodology that allows fast and reliable determination of the fatigue strength. It is based on monitoring the specimen stiffness changes at different stress levels, as an indicator of the evolution of fatigue damage. This new rapid fatigue test uses techniques available in many laboratories, as the DIC (Digital Image Correlation) technique and common extensometers. Moreover, the obtained data are easier to handle than infrared cameras or acoustic emission systems data, and the experimental procedure to determine the fatigue limit is more evident than in the self-heating method. Experiments have been conducted in TWIP (Twinning Induced Plasticity) steel, a material used for lightweighting the structural parts of vehicles. With their excellent energy absorption capacity, TWIP steels can satisfy the part requirements in terms of crash performance, while their high tensile strength can deal with the cyclic loads acting on chassis parts. Therefore, many efforts focus on improving the fatigue strength of TWIP steels through pre-straining and/or surface treatments. However, finding the best way to improve the fatigue resistance requires time and resources that often hinder the development of the material. For this reason, a TWIP steel has been selected to check the new rapid fatigue test. The prediction made using the proposed approach is validated by comparison with conventional staircase results and fatigue crack growth standardised tests. The good agreement allows proposing the new method as a fast and efficient way to determine the fatigue resistance in metals.Peer ReviewedPostprint (published version

Understanding the fatigue notch sensitivity of high-strength steels through fracture toughness

This study presents an innovative approach for selecting high-strength materials for fatigue dimensioning parts, considering both fracture toughness and fatigue performance. Warm and hot forming processes enable the construction of high-strength parts above 1000 MPa with complex geometries, making them suitable for lightweight chassis in automotive and freight applications. This research reveals that high-strength steels can experience up to a 40% reduction in fatigue performance due to manufacturing defects introduced during punching and trimming. Fracture toughness has been proposed as a good indicator of notch sensitivity, with a strong correlation of 0.83 between fracture toughness and fatigue notch sensitivity. Therefore, by combining fracture toughness measurements and fatigue resistance obtained through the rapid fatigue test, it becomes possible to quickly identify the most fatigue-resistant materials to deal with defects. Among the nine materials analysed, warm-formed steels show promising characteristics for lightweight chassis construction, with high fatigue resistance and fracture toughness exceeding the proposed fracture threshold of 250 kJ/m2.Peer ReviewedPostprint (published version

Effect of sandblasting on low and high-cycle fatigue behaviour after mechanical cutting of a twinning-induced plasticity steel

In the last years, car bodies are increasingly made with new advanced high-strength steels, for both lightweighting and safety purposes. Among these new steels, high-manganese or TWIP steels exhibit a promising combination of strength and toughness, arising from the austenitic structure, strengthened by C, and from the twinning induced plasticity effect. Mechanical cutting such as punching or shearing is widely used for the manufacturing of car body components. This method is known to bring about a very clear plastic deformation and therefore causes a significant increase of mechanical stress and micro-hardness in the zone adjacent to the cut edge. To improve the cut edge quality, surface treatments, such as sandblasting, are often used. This surface treatment generates a compressive residual stress layer in the subsurface region. The monotonic tensile properties and deformation mechanisms of these steels have been extensively studied, as well as the effect of grain size and distribution and chemical composition on fatigue behaviour; however, there is not so much documentation about the fatigue performance of these steels cut using different strategies. Thus, the aim of this work is to analyse the fatigue behaviour of a TWIP steel after mechanical cutting with and without sandblasting in Low and High-Cycle Fatigue regimes. The fatigue behaviour has been determined at room temperature with tensile samples tested with a load ratio of 0.1 and load amplitude control to analyse High-Cycle Fatigue behaviour; and a load ratio of -1 and strain amplitude control to determine the Low-Cycle Fatigue behaviour. Samples were cut by shearing with a clearance value of 5%. Afterwards, a part of the cut specimens were manually blasted using glass microspheres of 40 to 95 microns of diameter as abrasive media. The results show a beneficial effect of the sandblasting process in fatigue behaviour in both regimes, load amplitude control (HCF) and strain amplitude control (LCF) tests, when these magnitudes are low, while no significant differences are observed with higher amplitudes. low-cycle fatigue, high-cycle fatigue, mechanical cutting, sandblasting, high manganese steel, TWIP steel. © The Authors, published by EDP Sciences, 2018.Postprint (published version

Simulation of metal punching and trimming using minimal experimental characterization

This paper presents a validated finite element modeling approach for simulating shear cutting, needing a minimal amount of experimental characterization. Only one uniaxial tensile test and one force–displacement relationship from a punching experiment are needed for calibration, with maintained prediction accuracy compared to more experimentally demanding approaches. A key ingredient is the observation that the Lode angle parameter is close to zero in the fracture region, postulating that the fracture strain only depends on stress triaxiality, with one free calibration parameter. The true stress–strain behavior is provided from inverse modeling of the tensile test, whereas the fracture model is calibrated using the punching test. The model is verified for different materials by comparing force–displacement curves for punching experiments not used in the calibration. The prediction error for the intrusion is below 4%. A validation is made for two setups. The local residual stresses are measured using Focused Ion-Beam Digital Image Correlation (FIB-DIC). The simulated values are within the experimental bounds. Cut edge morphology and plastic strains obtained by nano-indentation mappings are compared to simulation results, showing a decent agreement. For trimming, the cut edge morphology prediction performance decreases at 17% cutting clearance while it is maintained over the whole range for punching. The predicted hardness values have a mean absolute percentage error below 7.5%. Finally, the effect of element size and remeshing is discussed and quantified. The minimal experimental characterization and simulation effort needed, enables an efficient optimization of the cutting process in the industry.Peer ReviewedPostprint (published version

Numerical simulation of a rapid fatigue test of high Mn-TWIP steel via a high cycle fatigue constitutive law

The generation of reliable data in the high cycle fatigue domain is crucial to support further metallurgic developments of fatigue optimized steel grades. Commonly employed for this aim, traditional standardized characterization methods are expensive and time-consuming. Thus, to circumvent these limitations, different accelerated fatigue testing methodologies have been proposed. In this work, the rapid fatigue test based on stiffness evolution is numerically reproduced using the finite element method for a specific grade of twinning-induced plasticity steel. A high cycle fatigue constitutive law grounded on the continuum damage mechanics framework is employed for this purpose. To adequately capture the material non-linear behavior observed in the experiments, a novel hardening–softening stress–strain curve for damage is proposed. The entire load history in the fatigue domain is modeled. A cycle-jump algorithm is used to improve the computational efficiency of the simulations. It is shown that a reduction of about 55% in the analysis elapsed time is reached by using this algorithm, while the result accuracy is maintained. Finally, the good agreement between numerical and experimental results, revealed by a maximum relative error smaller than 6.0%, evidences the potential of the present constitutive formulation to model the behavior of metals in the high cycle fatigue domain.This work has been done within the framework of the Fatigue4Light (H2020-LC-GV-06-2020) project: “Fatigue modeling and fast testing methodologies to optimize part design and to boost lightweight materials deployment in chassis parts”. This project has received funding from the European Union’s Horizon 2020 research and innovation program under grant agreement No 101006844. The work has been also supported by the Spanish Government program, Spain FPU17/04196. The authors gratefully acknowledge all the received support. Finally, they acknowledge the support received by the Severo Ochoa Centre of Excellence (2019-2023, Spain under the grant CEX2018-000797-S funded by MCIN/AEI/10.13039/501100011033, Spain .Peer ReviewedPostprint (published version

Identification of fracture toughness parameters to understand the fracture resistance of advanced high strength sheet steels

The fracture toughness of four advanced high strength steel (AHSS) thin sheets is evaluated through different characterization methodologies, with the aim of identifying the most relevant toughness parameters to describe their fracture resistance. The investigated steels are: a Complex Phase steel, a Dual Phase steel, a Trip-Aided Bainitic Ferritic steel and a Quenching and Partitioning steel. Their crack initiation and propagation resistance is assessed by means of J-integral measurements, essential work of fracture tests and Kahn-type tear tests. The results obtained from the different methodologies are compared and discussed, and the influence of different parameters such as specimen geometry or notch radius is investigated. Crack initiation resistance parameters are shown to be independent of the specimen geometry and the testing method. However, significant differences are found in the crack propagation resistance values. The results show that, when there is a significant energetic contribution from necking during crack propagation, the specific essential work of fracture (we) better describes the overall fracture resistance of thin AHSS sheets than JC. In contrast, energy values obtained from tear tests overestimate the crack propagation resistance and provide a poor estimation of AHSS fracture performance. we is concluded to be the most suitable parameter to describe the global fracture behaviour of AHSS sheets and it is presented as a key property for new material design and optimization.Peer ReviewedPostprint (author's final draft

DNA Methylomes Reveal Biological Networks Involved in Human Eye Development, Functions and Associated Disorders

This work provides a comprehensive CpG methylation landscape of the different layers of the human eye that unveils the gene networks associated with their biological functions and how these are disrupted in common visual disorders. Herein, we firstly determined the role of CpG methylation in the regulation of ocular tissue-specification and described hypermethylation of retinal transcription factors (i.e., PAX6, RAX, SIX6) in a tissue-dependent manner. Second, we have characterized the DNA methylome of visual disorders linked to internal and external environmental factors. Main conclusions allow certifying that crucial pathways related to Wnt-MAPK signaling pathways or neuroinflammation are epigenetically controlled in the fibrotic disorders involved in retinal detachment, but results also reinforced the contribution of neurovascularization (ETS1, HES5, PRDM16) in diabetic retinopathy. Finally, we had studied the methylome in the most frequent intraocular tumors in adults and children (uveal melanoma and retinoblastoma, respectively). We observed that hypermethylation of tumor suppressor genes is a frequent event in ocular tumors, but also unmethylation is associated with tumorogenesis. Interestingly, unmethylation of the proto-oncogen RAB31 was a predictor of metastasis risk in uveal melanoma. Loss of methylation of the oncogenic mir-17-92 cluster was detected in primary tissues but also in blood from patients.The research leading to these results was supported by European Research Council Advanced Grant EPINORC, RecerCaixa Foundation, Federación Española de Enfermedades Raras (FEDER), Federación Española de Enfermedades Neuromusculares (ASEM), Fundación Isabel Gemio, COST CM1406, Instituto de Salud Carlos III (PI/00816) and Health and Sciences Departments of the Catalan Government (Generalitat de Catalunya). M.E. is an Institució Catalana de Recerca i Estudis Avançats (ICREA) Research Professor. We thank the staff of the Biobank Facility at the Bellvitge Biomedical Research Institute (IDIBELL), Spanish National Cancer Research Center (CNIO), Institute of Rare Diseases Research (BioNER-ISCIII), Vall d’Hebron Research Institute (VHIR) and Banc de Sang i Teixits (BST) of the Catalan Ministry of Health. We also thank Dr. Mercedes Hurtado (Department of Ophthalmology, University and Polytechnic Hospital La Fe) and Dr. Dolores Pinazo (Department of Ophthalmology, Dr. Peset University Hospital) for obtaining samples from glaucomatous patients. We thank the patients and their families.S