Thermo-mechanical-metallurgical modeling for hot-press forming in consideration of the prior austenite deformation effect

A new anisotropic-asymmetric yield criterion covering wider stress states in sheet metal forming

Numerical modeling and analysis for forming process of dual-phase 980 steel exposed to infrared local heating

Damage growth and ductile fracture prediction is an urgent question for hot stamping operations. Numerous models for ductile fracture prediction in cold forming processes have been extensively developed. There is a real need to compare them to choose the best suitable one for hot stamping applications. In the present study, several ductile fracture criteria under the category of “uncoupled phenomenological criterion” and the “fully coupled damage criterion,” i.e., the continuum damage mechanics (CDM)-based Lemaitre model, were employed to compare their prediction capability on ductile failure prediction. These two categories of criteria were coded into an explicit thermo-mechanical finite element code dedicated to hot stamping simulation. Both hot forming limit and hot tensile tests of 22MnB5 steel were conducted in order to provide suitable data for calibrating these models. Numerical results of the applications of these models to the hot stamping process simulation of an automotive B-pillar were compared with the experimental ones. It is concluded that thermo-mechanical finite element analysis in conjunction with CDM-based Lemaitre model can be used as a reliable tool to predict ductile damage and fracture of 22MnB5 steel in hot stamping process.

Comparative study of ductile fracture prediction of 22MnB5 steel in hot stamping process

Laser welding-brazing of 5052 aluminum alloys and Al-Si coated 22MnB5 steel was carried out with a Zn-22Al filler metal. The influence of laser power on weld appearance, interfacial microstructure and mechanical properties were investigated. The weld morphology and the interfacial microstructure changed significantly with laser power. When the laser power was 1500 W, the intermetallic compounds (IMCs) at the FZ/steel interface consisted of Fe2Al7Si which was pre-existed in the Al-Si coating. As the laser power increased from 1700 W to 2100 W, the interfacial IMCs changed to Fe2Al5-xZnx and FeZn10. With the increase of the laser power, the tensile strength raised first and then decreased, the maximum value of 135.0 N/mm was obtained at 1900 W laser power. Differently, the bending angle first decreased and then increased with the increase of laser power. Numerical simulations showed that the maximum interfacial temperature increased from 835.7 ℃ to 1424.6 ℃ as the laser power increased from 1500 W to 2100 W. It resulted in the total dissolution of Fe2Al7Si and the newly generation of Fe2Al5-xZnx and FeZn10 therefore inducing the change of joint mechanical properties. 

The influence of laser power on microstructure and properties of laser welding-brazing of Al alloys to Al-Si coated 22MnB5 steel

Lightweight sheet metals are attractive for aerospace and automotive applications due to their exceptional properties, such as low density and high strength. Sheet metal forming (SMF) is a key technology to manufacturing lightweight thin-walled complex-shaped components. With the development of SMF, numerical simulation and theoretical modelling are promoted to enhance the performance of new SMF technologies. Thus, it is extraordinarily valuable to present a comprehensive review of historical development in SMF followed by state-of-the-art advanced characterization and modelling approaches for lightweight metallic materials. First, the importance of lightweight materials and their relationship with SMF followed by the historical development of SMF are reviewed. Then, the progress of advanced finite element technologies for simulating metal forming with lightweight alloys is covered. The constitutive modelling of lightweight alloys with an explanation of state-of-the-art advanced characterization to identify the constitutive parameters are presented. Then, the formability of sheet metals with major influencing factors, the techniques for measuring surface strains in SMF and the experimental and modelling approaches for determining the formability limits are clarified. Finally, the review is concluded by affording discussion of the present and future trends which may be used in SMF for lightweight metallic materials.

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A Review of Characterization and Modelling Approaches for Sheet Metal Forming of Lightweight Metallic Materials

Due to the recent needs for weight reduction in automotive industry, the hot stamping became a promising process to replace the classical press forming technology to form complex, high strength components. In the hot stamping process, the mechanical properties and accuracy of the final products are strongly dependent on temperature, cooling rate, time and so on. In this paper, the cooling time was selected as a key process parameter for the stamping of Coupled Torsion Beam Axle (CTBA) part and it was optimized using the finite element analysis which takes the deformation and strengthening induced by the cooling and phase transformation into account. Finally, the developed FE procedure was applied to the optimization of new cooling channel design of CTBA with different gage thickness, but maintaining cooling capacity with already manufactured CTBA as a reference.

Finite Element Simulation of Hot Stamping of Tubular Beam and Its Application to Die Channel Design

Characterization of mechanical properties and formability of 980 mpa grade high-strength steel sheet

In this paper, a new tool design for hot stamping taking advantage of both direct quenching and indirect die quenching is proposed to fabricate the coupled torsion beam axle which is formed from the original tubular-shaped part. This newly proposed hot stamping applies spray of the water before the upper die gets into contact with the tubular part, which significantly enhances the cooling capacity. For other region that cannot be covered by the direct spray, the conventional die quenching method in direct hot stamping process is used. Moreover, for the analysis of the deformation behavior during the proposed hot stamping process, the finite element analysis, which takes the deformation and strengthening induced by the cooling and phase transformation into account, has been carried out. From the analysis, the larger shape change when the cooling time is shorter than 15 s could be explained by the incomplete martensitic phase transformation and phase transformation plastic strain. When the cooling time is short the residual stress after cooling is much higher than those for the longer cooling times.

Phase transformation-based finite element modeling to predict strength and deformation of press-hardened tubular automotive part

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A Review of Characterization and Modelling Approaches for Sheet Metal Forming of Lightweight Metallic Materials

Finite Element Simulation of Hot Stamping of Tubular Beam and Its Application to Die Channel Design

Characterization of mechanical properties and formability of 980 mpa grade high-strength steel sheet

Phase transformation-based finite element modeling to predict strength and deformation of press-hardened tubular automotive part