Forming of High Strength Steel Sheets

Toyohashi University of Technology, Japan

Prof. Dr. Ken-ichiro Mori

Cold Stamping of High Strength Steel Sheets

1. High strength steel sheet
2. Springback in bending
3. Stretch flangeability
4. Fracture
5. Galling and seizure
6. Wrinkling
7. Shearing
8. Tailored blank
9. Plastic joining

Forming of lightweight automobile parts

Reduction in 100 kg weight: 1km/l
Material
High strength steel sheet (7.8)
Aluminium (2.7), Magnesium (1.8), Titanum (4.5)

Part
Hollow parts
One piece

Simulation
Finite element method

Production of automobiles in countries

UK

Germany

Russia

France

Italy

China

Spain

India

Korea

South Africa Thailand

Environmentally friendly automobiles: Hybrid

Honda Fit-Jazz
Toyota Prius

Toyota Prius PHV

Unit: 10,000 cars

Canada

USA

Japan

Brazil

Mexico

Brazil

Environmentally friendly automobiles: Electric

Nissan Leaf

Mitsubishi i-MiEV

Tesla Roadster

CO2 emission for producing automobile materials

CO2
CO2 emission

Mild steel
High tensile
strength steel
Aluminium

Reduction
in weight

Magnesium
Magnesium

Recycle

Carbon
fibers

Production

CO2 Emission per producing 1 kg material (kg)

Running time

Scrapping

High strength steel sheets

Specific strength for various sheet metals

DP steel TRIP steel

Sheet

Tensile
strength

Specific
gravity

Ultra high
strength steel

980 1470MPa

7.8

High strength
steel

490790MPa

7.8

63-101MPa

Mild steel SPCC

Aluminium alloy
A6061(T6)

340MPa

7.8

44MPa

310MPa

2.7

115MPa

Ferrite
Martensite
Retained austenite
Bainite

IF steel:

Elongation /%

Strength-tospecific gravity
ratio
126 188MPa

TRIP steel
DP steel
Martensite steel

Die quenching
1500

Ultra sheet

Tensile strength /MPa

High strength steel sheet

High Strength Steel Sheet, HSS, AHSS, Ultra HSS
Tensile strength: 440, 490, 590 780, 1180 MPa
Pmax/A0
Load

Mechanism of strengthening
of high strength steel sheet
Transformation

Pmax
Solid
solution
Mild steel

Displacement
A0: initial cross-sectional area

Precipitation

Martensite
Bainite

Precipitation
Bainite
Martensite
Yield stress ratio
Martensite

Hole expansion ratio (%)

Elongation (%)

Properties of high strength steel sheets

ULSAB-AVC (Ultra Light Steel Auto Body
- Advanced Vehicle Concept)
Martensite
Bainite

Precipitation

r-value

Bainite
Precipitation

Precipitation

Application of high strength steel

sheets to automobile body

Used steel sheets

36% of total weight

Used steel sheets

Results of ULSAB-AVC

Gasoline
Fuel
consumption

Weight

Collision
safety
Production cost

Diesel

Gasoline

Diesel

Application of high strength steel

sheets to automobile body

Mazda, Demio

Subaru Legacy
HSS
36.4%

Material percentage

Old
New

Mild steel
46%

Ultra HSS
12.8%

Alumimium
4.8%

High strength steel sheets: from 40% to 60%

Toyota Crown,
45% of body panels

8% reduction in weight

Mazda, Atenza, Roadstar

Mazda, Atenza: from 42% to
49%

Chang in percentage of use of HSS

Mazda, Roadstar, 1500MPa:

12% (green)

(a) 2004

Increase in strength and reduction in weight

Bumper

Bumper

Inner panel

Inner panel

Outer panel

Outer panel

(a) 2004

(b) 2014

80
60
40
20
0

Reduction in weight /%

Pillar

Increase in bending strength /%

Use of HSS in automobile body panels

Pillar

(b) 2014

500 1000 1500 2000

Tensile strength /MPa

40
20
0

500 1000 1500 2000

Tensile strength /MPa

Springback in bending

Cold Stamping of High Strength Steel Sheets

Ultra HSS

1. High strength steel sheet

2. Springback in bending

Mild steel

3. Stretch flangeability
4. Fracture
5. Galling and seizure

Springback: large
Accuracy of shape: low
Loading Compressive

6. Wrinkling
7. Shearing
8. Tailored blank

Unloading

9. Plastic joining

Deterioration in shape accuracy of formed parts

Tensile

Elastic recovery

Compressive
Tensile

Springback in hat-shaped bending of HSS

Tensile
strength

Springback

Wall wrap

Twisting

Longitudinal wrap

Effects of material and thickness

in V-shaped bending

Springback in bending
M
EI

Springback

R
R ~
~
E t

(bt2/4)

M Bending moment
I Geometrical moment of inertia (bh3/12)
Flow stress
E Young's modulus
t Thickness
t
Bend angle
R Radius

Springback / /

5
4
3
2
1
0

Bending/ angle /
(a) Material

angle
/
Bending
/
(b) Thickness

Effect of strength on springback

in hat-shaped bending

Effect of back pressure on springback

in U-shaped bending

Punch corner radius / thickness

Effect of strength on wrap in hat-shaped bending

Back pressure /MPa

Effect of blank holder force on wrap

in hat-shaped bending

Die corner radius / thickness

R /
Blank holder force /kN

800kN CNC Servo Press

Reduction in springback in V-shaped bending

Direct driving type

servo motor
Feedback control

90

ball screw

Botto
conventi
m
ti
dead
accuracy:onal
1m
speed:
centre150mm/s me

Reduction in thickness in bottoming

t
f=
t0

Sheet

9.6

90

t0

9.6

Deformation behaviour in V-shaped bending

Flow stress curve of sheets at room temperature

Large springback
1200

SPFC980Y 64.5 10 3 s 1
0.2 10 3 s 1

Flow stress /MPa

1000

(a) SPCC
(b) SPFC980Y
v=24mm/s, f=0%, T=0.5s
3 times slower

SPFC780Y 91.2 10 3 s 1
0.2 10 3 s 1

800

3 1
SPFC440 92.9 10 s 3

600

0.2 10 s 1

3 1
SPCC 95.6 10 s0.2 10 3 s 1

400

0.1 10 3 s 1

3 1
A5083 51.4 10 s

104.9 10 3 s 1
A1050

200
0

0.05

0.1

0.2 10 3 s 1

0.15

0.2

0.25

0.3

Strain

Relationship between springback and forming

speed in V-shaped bending (f=0%, T=0s)

Scatter of initial thickness of sheets

40

SPFC980YNominal

SPFC980Y
(DP),
SPFC440
(IF), SPCC

Sheet

6
4

Nominal
1.2mm
thickness

SPFC440

nominal

Number of sheets

Springback /

SPFC980YDP
SPFC440

30
SPCC

20

10

SPCC
0
-2
0

0
1.18

1.19

1.2

1.21

Initial thickness t0 / mm
10

20

30

40

50

Forming speed /mms-1

Relationship between springback and forming

speed in V-shaped bending (f=0%, T=0s)

Relationship between springback and

tensile strength

8
40
Springback /mm

Springback /

SPFC980Y, real
6
4
SPFC440

30

980MPa

20

590MPa

10

SPCC

270MPa
0

0
-2
0

10

20

30

Forming speed /mms-1

40

50

250

Required 0.5mm
tolerance

500
750
Tensile strength /MPa

1000

1.22

Springback angle
/ /

Effects of bottoming and

holding time at bottom dead centre for SPFC980Y

Distribution of stress in width direction just after

unloading for finishing reduction in thickness

8
/GPa

1.5

f=0%, T=0.1s

f=0.33%, T=0.1s

f=0.33%, T=0.5s

1.0
0.5
0
-0.5
-1.0

0
-2
0

-1.5

(a) f=0%
10

20
30
40
-1 -1
v / mms
Forming
/mms
speed

(b) f=0.33%

-2.0

50

Effect of bottoming

Prevention of springback by beads in side wall

Increase in stiffness
Springback
After
forming

Nominal
Die surface

Expectation for springback

Kaewtatip, P., Prasitkhetkhan, N., Khantachawana, A., Premanond, V.,
Hato, R., Sresomreong, B., Koga, N., Proc. 9th ICTP, (2008).

Prevention of springback by chamfering

Old shape

New shape

Chamfer shape

Prevention of springback by control of blank

holder force

Prevention of springback by crash forming

Prevention of springback by overrun inducing punch

(a) Draw bending (b) Crash forming without blank holder

Prevention of springback by overrun inducing punch

Prevention of springback by crash forming

Tensile strength /MPa

452
597
838
1025
1211
1520

Prevention of springback by crash forming

Prevention of springback and twisting

by restriking

(a) Drawing (b) Restriking

980MPa
Drawing

Restriking

Prevention of springback by slide locking

Prevention of springback and twisting

by chamfered bending and push-back forming
590MPa, 1.0 mm
Push Back

Chamfer

780MPa
(b) Restriking

(a) Bending

(a) Drawing

(b) Slide locking

Adjustment of die shape by finite element simulation

Effect of constitutive equations on calculated springback

by finite element simulation

FEM simulation

Isotropic model
Yoshida-Uemori model

NG

Stress (MPa)

Difference from product

Adjustment
OK

(a) Experimental result (980 MPa)

Strain

(a) Simulation

(b) 1st
adjustment

(c) 2nd
adjustment

Cold Stamping of High Strength Steel Sheets

(b) Isotropic model

Fracture in stretch flanging of high strength steel sheets

Cold stamping

1. High strength steel sheet

2. Springback in bending

(c) Yoshida-Uemori model

Shearing
Sheet

Bending

3. Stretch flangeability
4. Fracture
5. Galling and seizure

Stretch flanging

Sheared edge
780MPa high strength steel formed product

Tensile
Small
formability

6. Wrinkling
7. Shearing
8. Tailored blank
9. Plastic joining

Fracture

Properties of high strength steel sheets

Precipitation
Bainite
Martensite
Yield stress ratio
Martensite

Hole expansion ratio (%)

Elongation (%)

Steel sheets used for punching and stretch flanging

Martensite
Bainite

Precipitation

Bainite

r-value

Precipitation

Sheet

Thickness Yield stress Tensile

[mm]
[MPa]
strength [MPa]

Elongatio
n [%]

nvalue

JSC980Y

1.41

620

1027

18.7

0.12

JSC780Y

1.41

558

823

19.0

0.12

JSC590R

1.40

446

600

26.2

0.14

JSC440W 1.41

320

455

33.8

0.18

JSC390W 1.39

283

389

35.8

0.18

JSC270C

223

333

41.2

0.19

1.39

Precipitation

Shearing conditions
Stretch flanging conditions

Die
1.4

Punch

Die

Concave
blank
Punch

Velocity: 30mm/s

JSC980, JSC780

Sheet
holder
1.4

Blank

Punch

Blank

Sheet
holder

Die
R5

Punch

155o
L

155o

1.4

Sheet
holder

Sheet
holder

c=10, 15, 20, 25%

Clearance ratio

Die

1.4
2

R5 Blank
Burr side
Velocity: 30mm/s

Flange length, 1 mm interval

Relationship between limiting flanging ratio

and clearance ratio

Effect of clearance ratio of occurrence of fracture

JSC980YL=15mm

2mm
l0
1mm

0.1mm

Burni
sh

Fracture

No
fracture

No
fracture

Fracture

Surface

Sheared edge

(a) c =20%

Before bending

0.1mm

1mm

Fract
ure

Crack
l1
After bending

Surface

Sheared edge
(b) c =15%

Limiting flanging ratio:

Limiting flanging ratio /%

200

200

60

JSC780
40

JSC980

20

10

15

20

Clearance ratio /%

l1 - l0
l0

25

30

Upper die

Upper punch

s1

Lower die

Relationship between limiting expansion ratio

and tensile strength
60
Upper and lower punching
50
Limiting expansion ratio /%

Improvement of stretch flangeability by upper and

lower punching

Lower punch

Stroke of upper
punch

(b) Shearing by upper punch

s2

(a) Initial

Load of lower
punch

Stroke of lower
punch

(c) Shearing by lower punch

20
10
0

600
800
1000
Tensile strength /MPa

Smoothing of fracture surface on sheared edge

with conical punch in punching
Punching load P
Conical punch

Compression

Fracture
surface

Die

Blank
Sheet holder

12

Guide

Smoothing

Conical
punch
30

Sheet holder

Load

Shearing

Conventional
(c=20%t)

30

(d) Punching

Smoothing of fracture surface on sheared edge

with conical punch
Conical
punch

40

Stretch flanging
Blank (c=20%)

Sheet

Dir\e

Fracture
surface
side
Sheet holder
Blank (c=20%)
Die

10.72

Tensile

Sheared edge

Smoothing of fracture surface on sheared edge of

punched sheet (JSC980Y)

Smoothed sheared edge (JSC980Y)

0.3mm

(a) P=0 kN

(b) P=6 kN

(c) P=12 kN

30 m

0 m

(d) P=16 kN

(e) P=20 kN

(f) P=22 kN

(i) Surface (ii) Height

(a) P=0kN
(Punched edge)

(i) Surface (ii) Height

(b) P=22kN

Smoothing of fracture surface on sheared edge

with conical punch in punching
Die

Die

Sheet
holder

JSC390W

90 JSC980Y,
60 electrical discharge machining
30

Punch

15 2.5

JSC980Y
5
10 15 20
Sommthing load P /kN

Rollover
Burnished
Fracture
Smoothed
(b) P=2.5kN

Burnished

(c) P=9kN

60

00

Burr side

1.5

60

590MPa, no smoothing

40

0.5

20
0

Frature
2

4
6
Load P / kN

0.5mm
Burnished
Smoothed

Fracture
(b) P = 1 kN

4
6
P /kN

Sheared edge before and after smoothing

(JSC980Y, c=15%

(a) P = 0 kN

Blank

Smoothed

40
20

Conical
punch

80
Limiting stretch
flanging ratio /%

Rollover

80

Smoothing

Improvement of limiting stretch flanging

ratio (JSC780, c=20%)

1mm

100

Die
Blank
Blank
holder

Conical
punch 45

25

Sheared edge after smoothing (JSC780, c=20%)

(a) P=0kN

Punch

Concave sheet

(c) P = 2 kN

Fractre

Average surface roughness of

fracture surface Ra /m

120

Depth percentage /%

Sheet
holder

150

Improvement of limiting stretch flanging

ratio (JSC980Y, c=15%)
Limiting flanging ratio /%

Limiting expansion ratio /%

Improvement of limiting expansion ratio by

smoothing (JSC980Y)
210
JSC390W,
180
electrical discharge machining

60
50
40

590MPa,
no smoothing

30
20
10
0

0.5 1
1.5 2
Smoothing load P /kN

Reduction in tensile stress at corner

using gradual contact punch

Reduction in tensile stress at corner

using gradual contact punch

Die

Blank

Tensile
(a) Flat punch stress

Gradual contact punch

Gradual contact
punch

Reduction in
tensile stress

(b) During forming

(b) Gradual contact punch

(c) After forming

Shearing conditions

Stretch flanging conditions

Thick- Yield stress

Tensile
Elonga- Reduction
ness /mm
/MPa
strength /MPa tion /% in area /%
1.4

395

847

18.8

66

nvalue

JSC980Y

1.4

660

1014

16.4

45

0.15

1.2

864

1209

10.8

46

0.14

Blank
holder

Die
Clearance ratio
c =10, 15, 20, 25%
R50

Sheet
holder
2

Punch

Burr side

Punch

Punch
Blank

Die

Die

Software

LS-DYNA

Symmetry

1/2 model

Sheet

Elastic-plastic
shell elements

Tools

Rigid

Coefficient
of friction

0.15

Punch speed

100mm/s

Blank

Sheet
holder

W/W0 = 0.1-1
= 0-85o
L = 0-27mm

Distribution of longitudinal strain by flat punch

JSC780, =0o L=18mm

Calculated conditions of stretch flanging

Punch

Sheet
holder
R5
Punch R5

Die

Blank
holder

Punch

Blank holder

=155,130,120o

W0=200

Blank

Die
Blank

0.15

JSC1180Y

200

W0=200

1.
4

JSC780Y

45

(a) Before forming

Sheet

Reduction in
tensile stress

Die

10

Flat punch

Die

Longitudinal strain
0.5

0.4

0.3

0.2

0.1

Distribution of longitudinal strain by gradual contact punch

JSC780, =10o , W/W0=1.0 L=18mm)

Distribution of longitudinal strain by gradual contact punch

JSC780, L=17mm)

Gradual contact punch

Die

(a) Flat punch (=0o)

0.5

Longitudinal strain
0.5

0.4

0.3

0.2

0.1

0.4

0.3

0.2

0.1

Prediction of fracture at corner of 980MPa sheet

using gradual contact punch

20.9

22.5

Prediction of fracture at corner of 780MPa sheet

using gradual contact punch

(b) Gradual contact punch

=10o, W/W0=1.0)
Longitudinal strain

205.9
(a) Flat punch (=0o)

20.7

22.8

Fracture

Crack

(a) Flat punch, =180

205.2
No fracture
(b) Gradual contact punch=10o, W/W0=1.0)

Flat punch

W/W0=0.2, =45o
(b) JSC1180Y

21.9
13.7

W/W0=0.2, =45o
(a) JSC980Y

18.0

Flat punch

17.2

Improvement of limiting flange height by gradual

contact punch

No crack

(b) Gradual contact punch,

=170