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1 Great Designs in Steel is Sponsored by: ArcelorMittal Dofasco, ArcelorMittal USA, Nucor Corporation, Severstal North America, Inc. and United States Steel Corporation
2 AN EXPERIMENTAL STUDY ON SHEAR FRACTURE OF ADVANCED HIGH STRENGTH STEELS Hua-Chu (Michael) Shih United States Steel Corporation
3 Outline Shear Fracture in Stamping and Lab Simulative Test Bending Under Tension (BUT) Test Stretch Forming Simulator (SFS) Test Effects of Forming Variables Effects of Material Orientations Summary
4 Shear Fracture In Stamping and Lab Simulative Test 1 st STAGE OF STAMPING -BINDER COSURE (1) Upper Die Sheet Metal Stretch Forming Simulator (SFS)Test R Binder Lock Bead Upper die CL Punch opening die radius Lower Die Sheet Metal 1 st STAGE OF STAMPING BEGINNING OF DIE CLOSURE (2) Upper Die Binder Home θ CL Lower Die Lower die
5 Shear Fracture In Stamping and Lab Simulative Test 2 ND STAGE OF STAMPING INTERMEDIARY DIE CLOSURE (3) CL Upper Die o 90 Binder Lower Die Bend Under Tension (BUT) Test 90 o 2 ND STAGE OF STAMPING DRAW HOME (4) CL 90 o Binder Lower Die R Pin Sheet metal Back tension force V Pulling Force Upper Die Home Position
6 Bending Under Tension (BUT) Test Back tension force 90 R o Pin : fixed V Sheet metal Pulling force Variation of back tension force Varies R/T ( R= 1.5, 3, 5 and 14 mm) Fixed sliding speed Lubrication: Thin Teflon film
7 BUT Test Samples Increase Restraining Force Shear fracture Tangent point fracture Sidewall fracture No fracture - Low restraining
8 BUT Test Results 900 High tension Pulling Stress Engineering Stress (MPa) Low tension Shear fracture Tangent point fracture Sidewall fracture No fracture Sidewall fracture Tangent point fracture Shear fracture R/T
9 Stretch Forming Simulator (SFS) Test
10 Stress Calculations for SFS FREE BODY DIAGRAM OF STEADY STATE FORCES AT DIE RADIUS 0 F T + T cos = x f w 0 F y T sin = w ( ) φ ( ) φ FLOOR TENSION Restraining stress Tf DIE RADIUS T = w F y sin( φ ) (Wall tension) F X Wall stress T f = Fx + Tw cos( φ ) (Floor tension, restraining) WALL TENSION Tw TRANSDUCER MEASURED FORCES FY
11 SFS Test Measurable Wrap Angle & Forming Depth at Failure Upper Die R=18 mm Home Forming depth at failure Wrap Angle at failure Lower Die Lock Bead Lock Bead Fracture Θ2 Θ1 When R/T is fixed Θ2 : Better stretch bendability Θ1 : Poor stretch bendability
12 Normalized Stress (Wall Stress / UTS) SFS Test Results Smaller R/T for DP600 DP600 DP980 Critical R/T R/T DP600 DP780 Trip780 DP DP600 DP780 Trip780 DP R/T Wrap Angle at Failure (degree)
13 SFS Test - Effects of Restraining Forces Higher Restraining Force (A) (B) Fracture in radius-high restraining force (C) (D) No Restraining force Fracture on sidewall (less restraining force)
14 Failure Locations Upper Die R=18 mm Restraining Force Depth Fracture Lower Die (1) Fracture within radius Shear fracture (2) Fracture at the tangent Necking mixed failure (3) Fracture on sidewall Tensile type failure Fracture Strip Strip Strip Fracture Fracture
15 SFS Test - Effects of Tension Level SN2 SN1 460 mm 165 mm SN3 778 mm
16 SFS Test - Effects of Tension Level DP780, TRIP780 Transverse 1 mm Normalized Stress (Wall Stress / UTS) Critical R/T Tension Level Effects SN1 SN3 SN R/T DP780-SN1 DP780-SN2 DP780-SN3 Trip780-SN1 Trip780-SN2 Trip780-SN3
17 Fracture failure criterion 900 SN1-Shear fracture Wall Stress (MPa) Comparison of BUT and SFS test SN3-Shear fracture SN2-Tangent fracture SN3-Sidewall fracture SN3-Tangent fracture SN2-Shear fracture Shear Fracture Limit R/T BUT- sidewall BUT- tangent BUT- shear DP780-SN1 DP780-SN2 DP780-SN3 BUT-shear BUT-tangent BUT-sidewall
18 BUT-Stretch Forming Test (BUT-SF) Effects of Forming Variables - Lubrications and Forming Speeds Fixed: no movement 0 90 R Pin Sheet metal V Speed Control SFS Test on Pre-bend sample Upper Die 0 90 Lower Die Pre-bend sample
19 Different fracture locations - Lubrication Effects Normalized Stress (Wall Stress / UTS) Flat SFS Test 1 st stage of stamping DP780T-Normalized Stress TRIP780T-Normalized Stress Pre-bend Side wall fracture BUT-SF Test SFS-F-NT SFS-F-T SFS-PB-NT SFS-PB-T BUT-NT BUT-T Test Conditions 2 nd stage of stamping
20 Different fracture locations - Lubrication Effects DP780 T Flat sample Pre-bend sample NT T NT Fracture location shift T Better Lubrications SFS Test
21 Different fracture locations - Forming Speeds Effects DP780 L BUT-SF Test Fracture location shift close to die radius Fracture in radius Testing with Teflon NT V=0.25 m/min T NT V=1.5 m/min T NT V=3 m/min T NT T V=4.5 m/min NT T V=6 m/min
22 Different fracture locations - Forming Speeds Effects DP780 T, SFS Test Fracture location shift close to die radius NT T NT T V=0.25 m/min V=2.5 m/min NT T NT T V=5 m/min V=7.6 m/min
23 Material Orientation Effects Normalized Stress (Wall Stress / UTS) XK Material Orientation Effects DP600 DP780 50XK-Long 50XK-Trans DP600-Long DP600-Trans DP780-Long DP780-Trans R/T
24 Summary Shear fracture was re-created using Stretch Forming Simulator (SFS) test and the Bending Under Tension (BUT) test with various radius to thickness (R/T) ratios for DP600, DP780, DP980 and TRIP 780. Shear fracture depends not only on the R/T ratio but also on the tension level applied during bending. The higher grade AHSS tends to have a shear fracture transition zone at a higher R/T. Three types of specimen failures were observed: failure in radius (shear fracture), failure in the boundary or tangent point between the radius (necking mixed shear fracture) and the failure in the side wall (tensile failure). The transition from shear fracture to tensile type failure is very sensitive to the restraining condition or the tension level applied during the bending.
25 Summary The fracture limit curves of SFS test correlate very well with BUT test results. The tangent point fracture limit curve from BUT test should be considered as the shear fracture limit. This is recommended for use as the shear fracture failure criterion for computer simulations. Forming speeds and lubrication conditions are found to have effects on fracture locations and the fracture timing in the stamping. The higher speed and better lubrication tends to cause fracture on material close to die radius. Material orientations are found to have effects on fracture limit for the test materials. The longitudinal direction has a slightly higher fracture limit than the transverse direction of the test AHSS.
26 Great Designs in Steel is Sponsored by: ArcelorMittal Dofasco, ArcelorMittal USA, Nucor Corporation, Severstal North America, Inc. and United States Steel Corporation
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