Skip to main content
SpringerLink
Log in

Mechanical Bending Property of Ultra-High Strength Steel Sheets IN Roll Forming Process

  • Regular Paper
  • Published:
International Journal of Precision Engineering and Manufacturing Aims and scope Submit manuscript

Abstract

Ultra-high strength steel (UHSS) plays an important role in the automotive lightweight industry owing to its insubstantial weight and high specific strength. Roll forming is one of the effective forming processes for UHSS in the steel industry. In this study, the minimum bending radius is determined by roll forming experiments, taking into account the 1200MPa level of the V-profiled parts of UHSS. The ductile fracture criterion (DFC), which considers both the “tensile ductile fracture” and “shear ductile fracture,” is applied to predict the fracture of sheets in the roll forming process, where bending is the main deformation mode. A set of rolls is designed to investigate the fracture behavior in the roll forming process. In addition, finite element models (FEMs) are built and four sets of experiments are conducted to calibrate the fracture of the V-profiled parts for R/T = 1, 2, 3, and 4. Furthermore, the fracture time and fracture location of the V-profiled parts for R/T = 1 and 2 are predicted and the prediction results agree with the experimental results.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

Abbreviations

σ :

equivalent stress

K :

hardening coefficient

ε 0 :

initial strain

ε p :

equivalent plastic strain

n :

hardening index

E :

Young’s modulus

r :

anisotropy coefficient

σ p0.2 :

yield strength

σ b :

tensile strength

ε f :

equivalent plastic strain

σ 1 :

maximum principal stress

σ m :

hydrostatic pressure

σ 3 :

minimum principal stress

σ' 1 :

maximum principal stress deviator

σ' 3 :

minimum principal stress deviator

C 1 :

introduced material constant

C :

ductile fracture integral value

D :

damage value

References

  1. Oh, W.-J. and Lee, C.-M., “A Study on the Sheet Forming of the Lower Seat Rail Using 1180 Trip Steel,” International Journal of Precision Engineering and Manufacturing, Vol. 19, No. 2, pp. 299–302, 2018.

    Article  Google Scholar 

  2. Weiss, M., Marnette, J., Wolfram, P., Larrañaga, J., and Hodgson, P. D., “Comparison of Bending of Automotive Steels in Roll Forming and in a V-Die,” Key Engineering Materials, Vols. 504–506, pp. 797–802, 2012.

    Article  Google Scholar 

  3. Mäntyjärvi, K., Merklein, M., and Karjalainen, J. A., “UHS Steel Formability in Flexible Roll Forming,” Key Engineering Materials, Vols. 410–411, pp. 661–668, 2009.

    Article  Google Scholar 

  4. Lundberg, M. and Melander, A., “Finite Element Analysis of Roll Forming of UHSS Compared to Traditional Bending,” Proc. of IDDRG 2008 International Conference, pp. 331–338, 2008.

    Google Scholar 

  5. Badr, O. M., Rolfe, B., Zhang, P., and Weiss, M., “Applying a New Constitutive Model to Analyse the Springback Behaviour of Titanium in Bending and Roll Forming,” International Journal of Mechanical Sciences, Vol. 128, pp. 389–400, 2017.

    Article  Google Scholar 

  6. Hudgins, A., Matlock, D., Speer, J., and Van Tyne, C., “Predicting Instability at Die Radii in Advanced High Strength Steels,” Journal of Materials Processing Technology, Vol. 210, No. 5, pp. 741–750, 2010.

    Article  Google Scholar 

  7. Keeler, S. P. and Backofen, W. A., “Plastic Instability and Fracture in Sheets Stretched over Rigid Punches,” ASM Transactions Quarterly, Vol. 56, No. 1, pp. 25–48, 1963.

    Google Scholar 

  8. Goodwin, G. M., “Application of Strain Analysis to Sheet Metal Forming Problems in the Press Shop,” SAE Transactions, Vol. 77, Section 1, pp. 380–387, 1968.

    Google Scholar 

  9. Centeno, G., Bagudanch, I., Martínez-Donaire, A. J., Garcia-Romeu, M. L., and Vallellano, C., “Critical Analysis of Necking and Fracture Limit Strains and Forming Forces in Single-Point Incremental Forming,” Materials & Design, Vol. 63, pp. 20–29, 2014.

    Article  Google Scholar 

  10. Hussaini, S. M., Krishna, G., Gupta, A. K., and Singh, S. K., “Development of Experimental and Theoretical Forming Limit Diagrams for Warm Forming of Austenitic Stainless Steel 316,” Journal of Manufacturing Processes, Vol. 18, pp. 151–158, 2015.

    Article  Google Scholar 

  11. Ju, L., Mao, T., and Li, H., “An Experimental and Numerical Study of Forming Limits of AA5182-O,” The International Journal of Advanced Manufacturing Technology, Vol. 79, Nos. 1–4, pp. 221–228, 2015.

    Article  Google Scholar 

  12. Min, J., Lin, J., and Li, J., “Forming Limits of Mg Alloy ZEK100 Sheet in Preform Annealing Process,” Materials & Design, Vol. 53, pp. 947–953, 2014.

    Article  Google Scholar 

  13. Zeng, D., Chappuis, L., Xia, Z.C., and Zhu, X., “A Path Independent Forming Limit Criterion for Sheet Metal Forming simulations,” SAE International Journal of Materials and Manufacturing, Vol. 1, No. 1, pp. 809–817, 2009.

    Article  Google Scholar 

  14. Wang, H., Yan, Y., Jia, F., and Han, F., “Investigations of Fracture on DP980 Steel Sheet in Roll Forming Process,” Journal of Manufacturing Processes, Vol. 22, pp. 177–184, 2016.

    Article  Google Scholar 

  15. Sriram, S., Wong, C., Huang, M., and Yan, B., “Stretch Bendability of Advanced High Strength Steels,” SAE Technical Paper, No. 2003-01-1151, 2003.

    Google Scholar 

  16. Hora, P., Tong, L., Gorji, M., Manopulo, N., and Berisha, B., “Significance of the Local Sheet Curvature in the Prediction of Sheet Metal Forming Limits by Necking Instabilities and Cracks,” Proc. of MATEC Web of Conferences, Vol. 80, Article No. 11003, 2016.

  17. Ozturk, F. and Lee, D., “Analysis of Forming Limits Using Ductile Fracture Criteria,” Journal of Materials Processing Technology, Vol. 147, No. 3, pp. 397–404, 2004.

    Article  Google Scholar 

  18. Zeng, D., Xia, Z. C., Shih, H.-C., and Shi, M. F., “Development of Shear Fracture Criterion for Dual-Phase Steel Stamping,” SAE Technical Paper, No. 2009-01-1172, 2009.

    Google Scholar 

  19. Luo, M. and Wierzbicki, T., “Numerical Failure Analysis of a Stretch-Bending Test on Dual-Phase Steel Sheets Using a Phenomenological Fracture Model,” International Journal of Solids and Structures, Vol. 47, Nos. 22–23, pp. 3084–3102, 2010.

    Article  MATH  Google Scholar 

  20. Li, H., Fu, M. W., Lu, J., and Yang, H., “Ductile Fracture: Experiments and Computations,” International Journal of Plasticity, Vol. 27, No. 2, pp. 147–180, 2011.

    Article  Google Scholar 

  21. Huang, X. Z., Chen, J. S., and Chen, J., “Review on Fracture Criterion of Sheet Metal Forming,” Chinese Journal of Mechanical Engineering, Vol. 47, No. 4, pp. 23–31, 2011.

    Article  Google Scholar 

  22. Wang, P. and Qu, S., “Analysis of Ductile Fracture by Extended Unified Strength Theory,” International Journal of Plasticity, Vol. 104, pp. 196–213, 2018.

    Article  Google Scholar 

  23. Dizaji, S. A., Darendeliler, H., and Kaftanoğlu, B., “Prediction of Forming Limit Curve at Fracture for Sheet Metal Using New Ductile Fracture Criterion,” European Journal of Mechanics-A/Solids, Vol. 69, pp. 255–265, 2018.

    Article  MathSciNet  MATH  Google Scholar 

  24. Li, S., He, J., Gu, B., Zeng, D., Xia, Z. C., Zhao, Y., and Lin, Z., “Anisotropic Fracture of Advanced High Strength Steel Sheets: Experiment and Theory,” International Journal of Plasticity, Vol. 103, pp. 95–118, 2018.

    Article  Google Scholar 

  25. Jackiewicz, J., “Use of a Modified Gurson Model Approach for the Simulation of Ductile Fracture by Growth and Coalescence of Microvoids Under Low, Medium and High Stress Triaxiality Loadings,” Engineering Fracture Mechanics, Vol. 78, No. 3, pp. 487–502, 2011.

    Article  Google Scholar 

  26. Roth, C. C. and Mohr, D., “Ductile Fracture Experiments with Locally Proportional Loading Histories,” International Journal of Plasticity, Vol. 79, pp. 328–354, 2016.

    Article  Google Scholar 

  27. Deole, A. D., Barnett, M. R., and Weiss, M., “The Numerical Prediction of Ductile Fracture of Martensitic Steel in Roll Forming,” International Journal of Solids and Structures, Vols. 144–145, pp. 20–31, 2018.

    Article  Google Scholar 

  28. Oh, S. I., Chen, C. C., and Kobayashi, S., “Ductile Fracture in Axisymmetric Extrusion and Drawing—Part 2: Workability in Extrusion and Drawing,” Journal of Engineering for Industry, Vol. 101, No. 1, pp. 23–35, 1979.

    Article  Google Scholar 

  29. Brozzo, P., Deluca, B., and Rendina, R., “A New Method for the Prediction of Formability Limits in Metal Sheets, Sheet Metal Forming and Formability,” Proc. of the 7th Biennial Conference of the International Deep Drawing Research Group, 1972.

    Google Scholar 

  30. Rice, J. R. and Tracey, D. M., “On the Ductile Enlargement of Voids in Triaxial Stress Fields?” Journal of the Mechanics and Physics of Solids, Vol. 17, No. 3, pp. 201–217, 1969.

    Article  Google Scholar 

  31. Huang, J.-K. and Dong, X.-H., “Numerical Simulation and Experimental Verification of Ductile Fracture Criteria of Metals,” Materials Science and Technology, Vol. 18, No. 4, pp. 450–454, 2010.

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. School of Mechanical and Materials Engineering, North China University of Technology, Beijing, 100144, China

    Fei Han, Yun Wang & Zai-Lin Wang

Authors
  1. Fei Han
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yun Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Zai-Lin Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Fei Han.

Additional information

Fei Han Professor in the School of Mechanical and Materials Engineering, North China University of Technology. His research interest is theoretical study on roll forming process of sheet metal.

Yun Wang M.Sc. candidate in the School of Mechanical and Materials Engineering, North China University of Technology. His research interest is theoretical study on roll forming process of sheet metal.

Zai-Lin Wang M.Sc. candidate in the School of Mechanical and Materials Engineering, North China University of Technology. His research interest is theoretical study on roll forming process of sheet metal.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Han, F., Wang, Y. & Wang, ZL. Mechanical Bending Property of Ultra-High Strength Steel Sheets IN Roll Forming Process. Int. J. Precis. Eng. Manuf. 19, 1885–1893 (2018). https://doi.org/10.1007/s12541-018-0216-7

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12541-018-0216-7

Keywords

Search

Navigation