On modelling of shear fracture in deep drawing of a high-strength dual-phase sheet steel

The paper presents application of fracture behaviour characterisation results of a dual-phase sheet steel DP600 to an FEA of its deep-drawing for shear fracture prediction. The characterisation results were obtained with the help of a characterisation method based on a tensile test on a novel butterfly specimen and published previously by the authors. The aim of the present paper is to evaluate that characterisation method on a deep-drawing process. Based on the previous results of the authors, the fracture behaviour is modelled here with the help of the modified Mohr-Coloumb fracture model. The obtained FEA results reveal that shear fracture of the studied material is predicted too early by the used MMC fracture model. A novel adjustment of the model is proposed yielding infinitely high fracture strains at strongly pressure-superimposed stress states. As it is often the case in the state-of-the-art fracture characterisation of high-strenght sheet steels, such stress states were not tested during the previously performed fracture characterisation but occur during the studied deep drawing process. With the help of the adjusted MMC fracture model, it is possible to predict the crack initiation moment very accurately and the crack initiation location sufficiently accurately. © Published under licence by IOP Publishing Ltd

Finite element analysis regarding the forming behaviour of symmetric hybrid structures consisting of two sheet metal outer layers and a thermoplastic core

To face challenges like damping effects or weight reduction in the automotive sector, new hybrid material combinations are developed. One possibility is the combination of several symmetric material layers with varying material characteristics to achieve in the component production less weight and appropriate stiffness in comparison to components produced with sheet metal. This article deals with the characterization of deep drawing behaviour of layered sandwich structures. The behaviour of the several layers and the layer interaction have been taken into account for the technical design of a deep drawing process. A material layer characterization is performed. Instabilities as interlaminar failures, ruptures or wrinkling of the structure have been investigated as part of additional experimental characterization tests on the basis of various deep drawing process parameters. Finally, the experimental data is used as input for the numerical modelling and simulation of layered structures. The FE simulation includes the material behaviour of the layers and layer interactions with cohesive zone modelling. Based on the results an important contribution for prediction accuracy in the numerical simulation has been provided

Experimental Characterization and Material Modelling of an AZ31 Magnesium Sheet Alloy at Elevated Temperatures under Consideration of the Tension-Compression Asymmetry

Magnesium sheet alloys have a great potential as a construction material in the aerospace and automotive industry. However, the current state of research regarding temperature dependent material parameters for the description of the plastic behaviour of magnesium sheet alloys is scarce in literature and accurate statements concerning yield criteria and appropriate characterization tests to describe the plastic behaviour of a magnesium sheet alloy at elevated temperatures in deep drawing processes are to define. Hence, in this paper the plastic behaviour of the well-established magnesium sheet alloy AZ31 has been characterized by means of convenient mechanical tests (e. g. tension, compression and biaxial tests) at temperatures between 180 and 230 °C. In this manner, anisotropic and hardening behaviour as well as differences between the tension-compression asymmetry of the yield locus have been estimated. Furthermore, using the evaluated data from the above mentioned tests, two different yield criteria have been parametrized; the commonly used Hill'48 and an orthotropic yield criterion, CPB2006, which was developed especially for materials with hexagonal close packed lattice structure and is able to describe an asymmetrical yielding behaviour regarding tensile and compressive stress states. Numerical simulations have been finally carried out with both yield functions in order to assess the accuracy of the material models

Numerical analysis of a deep drawing process with additional force transmission for an extension of the process limits

By sheet metal forming processes the forming limits and part characteristics are defined through the process specific loads. In deep drawing processes the maximum deep draw ratios as well as the springback behaviour of the metal parts are depending on the stress distribution in the part material during the forming process. While exceeding the load limits, a failure in the material occurs, which can be avoided by additional force transmission activated in the deep drawing process before the forming limit of material is achieved. This contribution deals with numerical investigation of process effect caused by additional force transmission regarding the extension of the process limits. Here, the steel material HCT 600X+Z (1.0941) in thickness s 0 = 1.0 mm is analyzed numerically using the anisotropic model Hill48. This model is validated by the means of cup test by Swift. Both, the FEA of conventional and forming process with additional force transmission are carried out. The numerical results are compared with reference geometry of rectangle cup.DFG/BE169/139-

Numerical and experimental investigations on an extrusion process for a newly developed ultra-high-carbon lightweight steel for the automotive industry

In this study the material flow of a newly developed ultra-high-carbon lightweight steel (uhc-steel) with a high amount of aluminum was investigated in an extrusion process. Cylinder compression tests were performed for material characterization and frictional behaviour was determined by using ring compression tests. Numerical simulations were carried to determine the optimal die geometry as well as to calculate the process loads and dominated stresses in the die occurring during the process. Based on the numerical results, an extrusion process was designed and implemented. Experiments showed that the uhc-steel can be formed by extrusion however it is associated with a high wear rate.BMB

Automated Stamp Forming of Continuous Fiber Reinforced Thermoplastics for Complex Shell Geometries

This research describes the development of a fully automated forming process of continuous FRP to assemble a down scaled battery tray for a plug-in-hybrid automobile. The paper presents the results of forming experiments and a restraint approach to avoid wrinkling, an FEM forming simulation to detect the wrinkling behavior, shear effects and temperature trajectories for the consolidation at the end of the forming step, and a multi material gripper-system used for handling and preforming. The gripper system is capable of handling continuous FRP in different states and features a pneumatic stamp to pre-drape the heated organic sheet.BMBF/Open Hybrid LabFactor

Mechanical properties of co-extruded aluminium-steel compounds

Within the scope of the Collaborative Research Centre (CRC) 1153 novel process chains for the production of hybrid solid components by Tailored Forming are developed at the Leibniz Universität Hannover. The combination of e. g. aluminium with steel allows to produce hybrid compounds with wear-resistant functional surfaces and reduced weight. In these process chains, joining takes place as the first step to produce hybrid semi-finished products by friction welding, cladding, ultrasonic assisted laser welding or co-extrusion, which are subsequently subjected to various forming processes such as forging or impact extrusion. The coaxially joined hybrid semifinished components investigated in this work were produced by means of the lateral angular co-extrusion (LACE) process using the aluminium alloy EN AW-6082 and the case-hardening steel 20MnCr5. These semi-finished products shall be suited to produce hybrid bearing bushings by die forging in a subsequent process step. Initial investigations for the determination of the process parameters and the appropriate tool geometry were made using a steel rod. In future investigations, a steel tube will replace the steel rod in order to produce hybrid semi-finished products, which can be fully integrated into the process chain. The mechanical properties of the profile were determined at different positions along its length. For this purpose, the quality of the joining zone between aluminium and steel as a function of the profile position was examined by means of push-out tests. Moreover, the mechanical properties of the aluminium component's longitudinal weld seam were determined by micro-tensile-tests. © 2017 Trans Tech Publications, Switzerland

Molten Salt Storage for Power Generation

Storage of electrical energy is a key technology for a future climate-neutral energy supply with volatile photovoltaic and wind generation. Besides the well-known technologies of pumped hydro, power-to-gas-to-power and batteries, the contribution of thermal energy storage is rather unknown. At the end of 2019 the worldwide power generation capacity from molten salt storage in concentrating solar power (CSP) plants was 21 GWhel. This article gives an overview of molten salt storage in CSP and new potential fields for decarbonization such as industrial processes, conventional power plants and electrical energy storage

Local Heat Treatment in Draw Bending for Profiles of Manganese Boron Steel 22MnB5

Due to the increasing demand for vehicles with a low fuel consumption and consequently low emissions, lightweight construction is an important task in the automotive industry. High-strength profile parts reduce the total weight of the vehicle while maintaining a high bending-resistance. Draw bending combined with inductive sheet heating and subsequent cooling represents a cost-effective and economic concept for producing partially hardened profiles for small batch sizes. This paper deals with experimental investigations to optimize and examine heating and cooling in the process chain of draw bending. After designing the process by numerical simulation, the existing draw bending machine of the IFUM was expanded by an inductive heating unit and a cooling system. Subsequently, new experiments on the implementation of a heat treatment during draw bending were carried out with this machine. In the course of these experiments, the determined process limits were recorded based on the required drawing force, the temperature courses in the process and the respective hardness values. These values served to evaluate and validate the results of the numerical simulation. By means of heating the material before it enters the forming die, it could be shown that it is possible to form super high-strength-profile components through draw bending. The material was heated up to austenitization temperature by a surface inductor and cooled by the draw bending tool and the additional air cooling. The material used was the uncoated manganese-boron steel 22MnB5. Good results with regard to process and part quality were obtained by means of an upstream heating. The comparison with the simulation also showed a high degree of similarity and consequently confirmed the results of the numerical representation of the process. Thus the general feasibility of integrating a heat-treatment into a draw bending operation was successfully proved.DFG/BE 1691/146-

Numerical and experimental determination of cut-edge after blanking of thin steel sheet of DP1000 within use of stress based damage model

The proposed study focuses on blanking of thin steel sheets of Dogal1000DP +Z100MBO. Numerical and experimental investigations of the influence of clearance and punch speed on the cutting force and the geometry of the sheared edge were done. Tensile and stack compression test at elevated temperatures has been chosen to determine the flow and fracture behavior of Dogal1000DP +Z100MBO at different stress states. It is shown that the flow curve determined by stack compression test leads to better results in force - displacement prediction of a blanking process compared to determination of flow curve by tensile test. Stress based fracture criterion were chosen to describe damage behaviour. Moreover significant influence of fracture locus for negative stress triaxialities on the geometry of the numerically predicted sheared edge is shown