Effect of steel forming on vehicle side impact behavior

2021 ◽  
Vol 63 (12) ◽  
pp. 1112-1115
Author(s):  
Emre Doruk
Keyword(s):  
Plastic Deformation ◽  
Impact Analysis ◽  
Thickness Distribution ◽  
High Strength ◽  
Side Impact ◽  
Impact Behavior ◽  
Vehicle Body ◽  
Forming Process ◽  
Sheet Metal Parts ◽  
Steel Sheets

Abstract Despite the seemingly daily development of high-strength new generation steel sheets, steel sheets still remain the most important engineering material used in a vehicle body. These steel parts in a vehicle body, meant to absorb energy during impact, are generally produced by steel forming methods. These steel forming operations may contain processes such as deep drawing, bending, cutting, spring back, spinning. According to the production conditions and type of processes used during the production of sheet metal parts, thinning, thickening, plastic deformation, folding, tearing and wrinkling may occur. In order to achieve more reliable impact simulations, these effects in the forming process should be conferred on impact analysis. Within the scope of this study, an analysis of the critical parts in steel forming that absorb the most energy during the side impact was conducted – first for vehicles. In a subsequent impact analysis, the effects of changes (thickness distribution, residual stress, plastic deformation, etc.) during steel forming were examined.

Quadrilateral Shape Rib Forming by Roll Forming Process

2018 ◽  
Vol 878 ◽  
pp. 296-301
Author(s):  
Dong Won Jung
Keyword(s):  
Automotive Industry ◽  
High Strength Steel ◽  
Numerical Study ◽  
Thickness Distribution ◽  
High Strength ◽  
Metal Sheet ◽  
Product Performance ◽  
Roll Forming ◽  
Forming Process ◽  
Roll Forming Process

The roll forming is one of the simplest manufacturing processes for meeting the continued needs of various industries. The roll forming is increasingly used in the automotive industry to form High Strength Steel (HSS) and Advanced High Strength Steel (AHSS) for making structural components. In order to reduce the thinning of the sheet product, traditionally the roll forming has been suggested instead of the stamping process. The increased product performance, higher quality, and the lowest cost with other advantages have made roll forming processes suitable to form any shapes in the sheets. In this numerical study, a Finite Element Method is applied to estimate the stress, strain and the thickness distribution in the metal sheet with quadrilateral shape, ribs formed by the 11 steps roll forming processes using a validated model. The metal sheet of size 1,000 × 662 × 1.6 mm taken from SGHS steel was used to form the quadrilateral shape ribs on it by the roll forming process. The simulation results of the 11 step roll forming show that the stress distribution was almost uniform and the strain distribution was concentrated on the ribs. The maximum thinning strain was observed in the order of 15.5 % in the middle rib region possibly due to the least degree of freedom of the material.

Finite Element Analysis and Formability Test on Incremental Forming of IS:513 CR3 Steel Sheets

2015 ◽  
Vol 766-767 ◽  
pp. 1109-1115
Author(s):  
S. Chezhian Babu ◽  
V.S. Senthil Kumar
Keyword(s):  
Metal Forming ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Forming Process ◽  
Element Analysis ◽  
Steel Sheets ◽  
Automobile Body ◽  
Metal Forming Process ◽  
High Flexibility ◽  
Forming Methods

Incremental forming is a recent sheet metal forming process that has high flexibility and repeatability. Unlike conventional forming methods this process is applicable mainly in the production of prototypes or small batches of automobile body panels, headlight reflectors, etc. In this investigation IS 513 CR3 Deep Drawing quality steel sheets of thickness 0.6 mm were incrementally formed into pyramids to study their formability characteristics. Experiments were conducted under three different spindle speeds (1000, 1500 and 2000 rpm), three tool feeds (1200, 1400 and 1600 mm.min-1) and three step depths (0.4, 0.5, and 0.6 mm). Forming time, thickness distribution and formability of the final components were studied. FEA models were created using Abaqus software and validated with experimental results.

Plastic Deformation Behavior of High Strength Cast Aluminium Cylinder in Hot Power Backward Spinning

2013 ◽  
Vol 303-306 ◽  
pp. 2769-2772 ◽  
Author(s):  
Z.H. Guo ◽  
E.L. Wang ◽  
Gang Yao Zhao ◽  
R.Y. Zhang ◽  
P. Fang
Keyword(s):  
Plastic Deformation ◽  
Metal Forming ◽  
High Strength ◽  
Fe Model ◽  
Adaptive Meshing ◽  
Forming Process ◽  
Theoretical Evaluation ◽  
Plastic Deformation Behavior ◽  
Metal Forming Process ◽  
Key Techniques

The hot power backward spinning(HPBS) of the high strength cast aluminums (HSCA) cylinder is a complex metal forming process. To analysis the plastic deformation of HSCA cylinder in HPBS process, a 3D coupled thermo-mechanical FE model of the process was built under the ABAQUS/explicit environment based on the solution of several key techniques, such as heat boundary condition treating, material properties definition, ALE adaptive meshing technology, etc., and verified by theoretical evaluation. Then simulation and analysis of HPBS of the process were carried out. The results show that the strain gradient which leads to the serious inhomogeneous deformation is produced in the thickness direction of the workpiece during the process.

scholarly journals Experimental Analysis of the Feasibility of Shaving Process Applied for High-Strength Steel Sheets

2016 ◽  
Vol 2016 ◽  
pp. 1-6 ◽  
Author(s):  
Wiriyakorn Phanitwong ◽  
Arkarapon Sontamino ◽  
Sutasn Thipprakmas
Keyword(s):  
High Strength Steel ◽  
Steel Sheet ◽  
High Strength ◽  
Forming Process ◽  
Steel Sheets ◽  
Metal Sheets ◽  
Metal Forming Process ◽  
New Material ◽  
The Relationship ◽  
High Ultimate Strength

In recent years, the engineered materials were developed to improve their mechanical properties. A high-strength steel sheet is one of them, developed to serve the requirement of reducing weight of vehicles. Therefore, as a new material, many researches have been carried out to examine the use of sheet metal forming process applied for high-strength steel sheet. However, the feasibility of shaving process applied for it has not been investigated yet. In the present study, this feasibility was revealed by using experiments on two types of high-strength steel sheets: SAPH 440 and SPFH 590Y (JIS). The relationship between shaved surface feature and shearing clearance of high-strength steel sheets corresponded well with those of their conventional metal sheets. However, due to the high ultimate strength of these materials, it was revealed in this present study that there were not any suitable conditions of shaving process that could be applied to achieve the requirements of smooth cut surface overall material thickness.

scholarly journals An investigation of the Formability Behaviour of High Strength Aluminium Alloys Using Different Heat Assisted Forming Processes

2021 ◽  
Author(s):  
M. Schmiedt ◽  
J.M. Schlosser ◽  
R. Schneider ◽  
W. Rimkus ◽  
D.K. Harrison
Keyword(s):  
Sheet Metal ◽  
Aluminium Alloys ◽  
High Strength ◽  
Forming Limit ◽  
Forming Process ◽  
Sheet Metal Parts ◽  
Specific Strength ◽  
Geometrical Complexity ◽  
Process Route ◽  
Forming Behaviour

The usage of ultra-high strength aluminium alloys (EN AW-7000 series) offers a great weight saving potential due to the high rigidity and specific strength values. Various heat assisted forming technologies have been developed in order to improve the limited formability at room temperature and thus to be able to increase the geometrical complexity of such sheet metal parts. In this study the forming behaviour of EN AW-7021 sheet metal alloy is described as a function of the forming process and the corresponding temperature profile. The forming limit curves (FLCs) are obtained by experimental Nakajima tests using the Warmforming, Hotforming, extended Hotforming and W-Temper process route. For this purpose, a Nakajima testing tool is designed according to ISO 12004 standard which allows operating temperatures of up to 200 °C.

Comparison of some Final Part Geometrical Characteristics of Cylindrical Cups Manufactured by Deep-Drawing and Two-Point Incremental Sheet Forming

2009 ◽  
Vol 410-411 ◽  
pp. 355-363 ◽  
Author(s):  
Babak Taleb Araghi ◽  
Markus Bambach ◽  
Gerhard Hirt
Keyword(s):  
Sheet Metal ◽  
Deep Drawing ◽  
Thickness Distribution ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Surface Strain ◽  
Forming Process ◽  
Sheet Metal Parts ◽  
Part Surface ◽  
Metal Forming Process

Asymmetric incremental sheet forming (AISF) is a new sheet metal forming process in which sheet metal parts are produced by CNC-controlled movements of a simple ball-headed forming tool. Despite its flexibility and successful application in many cases, AISF has not yet been established in an industrial context due to some still existing process limits such as severe thinning, which strongly depends on the inclination of the part surface, as well as a limited geometric accuracy due to springback. Furthermore, there is little knowledge available about the properties of parts produced by AISF, especially in comparison to deep-drawn parts. The aim of the present paper is to compare cylindrical cups manufactured by deep-drawing and AISF regarding the resulting strain and thickness distribution. For AISF, different forming strategies were applied. Comparisons of the wall thickness and surface strain distributions show similar results for the cup produced by deep-drawing and the best cup produced by AISF, but the surface strains and the sheet thinning in the parts formed by AISF were larger than in the deep-drawn part.

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