Development of a Damage Prediction System for Bending and Cutting of High Strength Steels

2013 ◽  
Vol 554-557 ◽  
pp. 2479-2486
Author(s):  
Peter Horst Vatter ◽  
Sven Hildering ◽  
Ioannis Tsoupis ◽  
Marion Merklein
Keyword(s):  
Industrial Application ◽  
Early Stage ◽  
Rolling Direction ◽  
High Strength Steels ◽  
Software Tool ◽  
High Strength ◽  
Material Strength ◽  
Punch Force ◽  
Steel Grades ◽  
Cutting Operation

Abstract. The application of modern high strength low alloyed steels (HSLA) and advanced high strength steels (AHSS) for structural and safety relevant components in the automotive industry offers the advantage of combining low specific weight with high material strength. Typical manufacturing processes for these steel grades are bending and cutting operations. The forming and cutting potential of these innovative steel grades is different to conventional steels as the process and the damage behaviour is changing. In bending operations cracks occur at the outer bending edge, whereas in cutting operations delamination can appear at the sheared edge. These damages, even though they are small, can initiate the component to fail. For a reliable use of such materials in industrial application a method for the process design is essentially needed. In particular, damages have to be predicted at an early stage. In industrial application damage is detected by a trial-and-error approach causing significant work and a high failure rate. A system for an offline assessment of the risk of failure is unknown so far. In the scope of this work, a method is presented to describe the damaging behaviour of both, bending and cutting operations, by theoretical metamodels. In order to generate a database experiments were carried out using different high strength steels. The main influence factors have been varied, such as the rolling direction, the punch-to-die clearance and the cutting contour in the cutting operation. The bending was investigated using an air-bending process varying the bending angle, the bending radius and the rolling direction. To calculate further sampling points a finite element model has been developed and validated against the experimental data. The damage criterion of Lemaître has been applied. The necessary parameters were determined by reverse identification by means of the major strain for the bending operation and by the punch force-punch stroke curve for the cutting operation. To build up a system for the prediction of the damage the gained data basis was approximated by mathematical functions. An error analysis was carried out showing good accordance. In doing so, a metamodel for the occurrence of damages could be established. The functions are implemented in a software tool which allows the user to determine the failure probability for a given parameter set.

Usability Testing of Ultra High-Strength Steels

2012 ◽  
Author(s):  
Jouko A. Heikkala ◽  
Anu J. Väisänen
Keyword(s):  
Tensile Strength ◽  
Plate Thickness ◽  
Rolling Direction ◽  
High Strength Steels ◽  
High Strength ◽  
Structural Steels ◽  
Test Material ◽  
Material Strength ◽  
Machining Parameters ◽  
Usability Tests

New ultra high strength (UHS) steels have been developed in order to get advantages in machine design and construction. Following benefits can be obtained for example: - less material usage due to lighter constructions; - better payload and less fuel consumption in vehicle industry; - energy saving in material production. A rough distinction of structural steels can be defined to ductile steels, with tensile strength less than 300 MPa, and high strength steels, up to 700 Mpa. A steel material can be defined as UHS steel when the tensile strength exceeds 700 MPa. Steels with yield strength of 1500 Mpa have been developed so far. UHS steels can also be divided into structural steels and wear resistant steels. With the tensile strength also the hardness increases and the tensile strain decreases. That causes several difficulties when the material is processed into products. Especially mechanical processing like bending, machining and shearing gets difficult as the material strength increases. That causes problems for the construction material users to find the proper manufacturing methods in production. In Oulu University Production Technology Laboratory material processing tests have been performed during several years in co-operation with the local steel manufacturer. The usability tests comprise mainly of bending and machining tests. Shearing and welding tests have been made to a smaller extent. Also laser treatment has been used for local heat conditioning in order to improve the bending and shearing properties, but these techniques are not yet widely used in production. The bending tests are carried out with standard bending tools and test steel plates with standard dimensions. The plate thickness varies depending on the test material. The target is to determine the reliable minimum bending radiuses whereby the plate can be bent without failure, from both sides and along the rolling direction and orthogonally to that. Also the springback angle is measured and the bent surfaces are evaluated according to several criteria. When necessary, also the mechanical testing of the formed material is carried out. The machining tests are made mainly by drilling. Also some milling tests have been performed. Drilling is a convenient way of machining testing because a substantial amount of holes can be drilled in one test plate. The drilling power can be observed precisely by monitoring the spindle power. Also a variety of different tool types can be used, from uncoated HSS drills to boring tools with indexable inserts. The optimal machining parameters (feed and speed) will be defined according to maximum tool life and minimum machining costs.

Failure Strain Criterion Accounting for the Effect of Material Strength

2021 ◽  
Author(s):  
N. Baghous ◽  
I. Barsoum
Keyword(s):  
Stress State ◽  
Ultimate Strength ◽  
Failure Criterion ◽  
Stress Triaxiality ◽  
Ductile Failure ◽  
High Strength Steels ◽  
Local Failure ◽  
Material Strength ◽  
Lode Parameter ◽  
Steel Grades

Abstract The objective of this study is to investigate the effect of the Lode parameter on different material strengths. Recent work has shown that ductile failure highly depends on the stress state characterized by both the stress triaxiality T and the Lode parameter L, which is related to the third deviatoric stress invariant. Thus, for six different steel grades, two different specimen geometries were manufactured to account for two different Lode parameters (L = −1 and L = 0), whereas T is controlled by introducing different sized notches at the center of the specimens. By performing tensile experiments and running finite element simulations, the ductile failure loci of the six materials showed variations between the two specimen geometries, indicating that the failure highly depends on the stress state characterized by both T and L. This indicates the need to reassess the ductile local failure criterion in the ASME codes that only accounts for T as a stress state measure. A Lode sensitivity parameter LS is defined based on the experimental results and revealed that the steel grades with ultimate strength higher than a certain threshold value (450 MPa) exhibit sensitivity to the Lode parameter, and the results showed that the LS increases with increase in the ultimate strength of the steel grade. The results were incorporated to enhance the original ASME local failure criterion by accounting for T, L, and LS to accurately assess ductile failure in high-strength steels.

Expulsion Intensity Monitoring and Modeling in Resistance Spot Welding Based on Electrode Displacement Signals

2020 ◽  
Author(s):  
Yu-Jun Xia ◽  
Yan Shen ◽  
Lang Zhou ◽  
Yong-Bing Li
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Low Carbon Steel ◽  
Sheet Thickness ◽  
High Strength Steels ◽  
High Strength ◽  
Material Strength ◽  
Low Carbon ◽  
Resistance Spot ◽  
Electrode Displacement

Abstract Weld expulsion is one of the most common welding defects during resistance spot welding (RSW) process especially for high strength steels (HSS). In order to control and eventually eliminate weld expulsion in production, accurate assessment of the expulsion severity should be the first step and is urgently required. Among the existing methods, real-time monitoring of RSW-related process signals has become a promising approach to actualize the online evaluation of weld expulsion. However, the inherent correlation between the process signals and the expulsion intensity is still unclear. In this work, a commonly used process signal, namely the electrode displacement and its instantaneous behavior when expulsion occurs are systematically studied. Based upon experiments with various electrodes and workpieces, a nonlinear relation between the weight of expelled metal and the sudden displacement drop accompanied by the occurrence of weld expulsion is observed, which is mainly influenced by electrode tip geometry but not by material strength or sheet thickness. The intrinsic relationship between this specific signal feature and the magnitude of expulsion is further explored through geometrical analysis, and a modified analytical model for online expulsion evaluation is finally proposed. It is shown that the improved model could be applied to domed electrodes with different tip geometries and varying workpieces ranging from low carbon steel to HSS. The error of expulsion estimation could be limited within ±20.4 mg (±2σ) at a 95% confidence level. This study may contribute to the online control of weld expulsion to the minimum level.

Structural Performance Evaluation of Built-Up Stub Steel Column with Various Steel Grades under Concentric Loading

2015 ◽  
Vol 764-765 ◽  
pp. 127-131
Author(s):  
Yang Yang ◽  
Kang Min Lee ◽  
Keun Yeong Oh ◽  
Sung Bin Hong
Keyword(s):  
Tensile Strength ◽  
High Strength Steel ◽  
Local Stability ◽  
Experimental Studies ◽  
High Strength Steels ◽  
High Strength ◽  
Design Criteria ◽  
Stability Criteria ◽  
Steel Grades ◽  
Concentric Loading

The current local stability criteria (KBC2009, AISC2010) are enacted through theoretical and experimental studies of ordinary steels, but the mechanical properties of high strength steels are different from ordinary steels. The high strength steel in the applicability of design criteria should be needed to review because of increasing market demanding for high strength steel in the high-rise and long span buildings. In this study, stub columns of H-shaped and box section with various steel grades subjected to concentric loading were investigated, and these steels were checked to the applicability of current local stability criteria. The difference between the ordinary steel and high strength steel was compared. As a result of comparison with various steel grades, most specimens were satisfied with the design criteria, but some specimens with lower tensile strength were not reached the required strength. It is considered that the uncertainty of material was the higher when the tensile strength of material was the lower.

Fatigue-Corrosion of High Strength Steels in Synthetic Seawater under Cathodic Protection

2020 ◽  
Vol 841 ◽  
pp. 294-299
Author(s):  
Sergio Lorenzi ◽  
Cristian Testa ◽  
Marina Cabrini ◽  
Francesco Carugo ◽  
Luigi Coppola ◽  
...  
Keyword(s):  
Cathodic Protection ◽  
Fatigue Behavior ◽  
High Strength Steels ◽  
High Strength ◽  
Loading Frequency ◽  
Offshore Pipelines ◽  
Synthetic Seawater ◽  
Steel Grades ◽  
Protection Potential ◽  
Fatigue Corrosion

The paper is aimed to the study of the corrosion-fatigue behavior of high strength steels for offshore pipelines. Tests have been performed in order to study fatigue crack growth in synthetic seawater under cathodic protection. The tests have been carried out on three different steel grades from 65 to 85 ksi with tempered martensite and ferrite-bainite microstructures. The effect of stress intensity factor, cathodic protection potential and cyclic loading frequency is shown.

Incremental Bending of Ultra-High-Strength Steels

2011 ◽  
Vol 473 ◽  
pp. 53-60 ◽  
Author(s):  
Antti Määttä ◽  
Kari Mäntyjärvi ◽  
Jussi A. Karjalainen
Keyword(s):  
Automotive Industry ◽  
Rolling Direction ◽  
High Strength Steels ◽  
High Strength ◽  
Roll Forming ◽  
Complex Phase ◽  
Bending Angle ◽  
Bending Radius ◽  
Ultra High Strength Steels ◽  
Traditional Manner

Utilisation of ultra-high-strength steels (UHS) has increased, particularly in the automotive industry. By using these materials vehicle structures can be lightened. However, one of the problems of UHS is weak formability. Materials fracture easily with small bending radii and the minimum bending radii are rather large. In this study, the tested materials were complex phase (CP) bainitic-martensitic UHS steels (YS/TS 960/1000 and 1100/1250). The steels were incrementally bent with a press brake in the rolling direction and perpendicular to it, and the final bending angle was 90 degrees. The incremental bending angles were 150°, 130°, 110° and 90°. The punch was unloaded after every incremental bending step. The test materials were bent with different bending radii. The aim was to find the minimum bending radius which produces an acceptable bend. Every incremental bend was compared with a bending performed in the traditional manner. The aim of this study was to examine how well the results of incremental bending compare to roll forming. In addition, clarification studies of when the bend started to fracture were made. It is well known that steels are more efficiently bent by roll forming compared with traditional bending. The results presented in this study demonstrate that incremental bending does not produce better results than traditional bending. Nevertheless, it has been shown that the examined steels can be bent incrementally against manufacturer’s recommendations.

Fatigue Assessment of Tubular Automotive Components in Presence of Inhomogeneities

2004 ◽  
Author(s):  
Stefano Beretta ◽  
Herna´n Juan Desimone ◽  
Andrea Poli
Keyword(s):  
Fatigue Limit ◽  
Detrimental Effect ◽  
Fatigue Behavior ◽  
High Strength Steels ◽  
High Strength ◽  
Probability Of Failure ◽  
Integral Approach ◽  
Material Strength ◽  
Automotive Components ◽  
Tubular Components

Tubular automotive components, e.g. stabilizers and half shafts, are components subjected to fatigue. In order to assess fatigue behavior of such components, it is important to know both the real load conditions as well as the material strength against multi-axial fatigue. For the second point, a detrimental effect in the fatigue limit of high strength steels is given by the defects present in the component, coming from the material (such as microinclusions, microvoids, etc) or for the process (e.g. handling marks). An integral approach in order to assess fatigue limit of tubular components is proposed. The attention is focused onto planar inhomogeneities, which are the most common in tubular products, though the methodology can be extended to different defect-shapes. The method is applied together with a probabilistic model, in order to analyze the probability of failure. In particular, two different processes (in terms of inhomogeneities present in the final component) are compared, and the results allow to evaluate, for example, the admissible load for the desired (or design) level of failure probability for the component.

The Role of Niobium in Lightweight Vehicle Construction

2007 ◽  
Vol 537-538 ◽  
pp. 679-686 ◽  
Author(s):  
Hardy Mohrbacher ◽  
Christian Klinkenberg
Keyword(s):  
Grain Refinement ◽  
High Strength Steel ◽  
Mechanical Performance ◽  
High Strength Steels ◽  
High Strength ◽  
Interstitial Free ◽  
Niobium Microalloying ◽  
Hsla Steels ◽  
Steel Grades ◽  
Different Characteristics

Modern vehicle bodies make intensive use of high strength steel grades to improve the weight and the mechanical performance simultaneously. A broad range of medium and extra high strength steel grades is available. These steel grades have different characteristics concerning strength, formability and weldability. For many steel grades microalloying by niobium is the key to achieve their characteristic property profile. In HSLA steels niobium enhances the strength primarily by grain refinement. In interstitial free high strength steels niobium serves as a stabilizing element and also assists in obtaining the bake hardening effect. Some modern multiphase steels rely on niobium to achieve additional strength via grain refinement and precipitation hardening. Microstructural control provides a way to further optimize properties relevant to automotive processing such as cutting, forming and welding. The relevance of niobium microalloying in that respect will be outlined.

Expulsion Intensity Monitoring and Modeling in Resistance Spot Welding Based on Electrode Displacement Signals

2020 ◽  
Vol 143 (3) ◽  
Author(s):  
Yu-Jun Xia ◽  
Yan Shen ◽  
Lang Zhou ◽  
Yong-Bing Li
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Low Carbon Steel ◽  
Sheet Thickness ◽  
High Strength Steels ◽  
High Strength ◽  
Material Strength ◽  
Low Carbon ◽  
Resistance Spot ◽  
Electrode Displacement

Abstract Weld expulsion is one of the most common welding defects during the resistance spot welding (RSW) process, especially for high strength steels (HSS). In order to control and eventually eliminate weld expulsion in production, accurate assessment of the expulsion severity should be the first step and is urgently required. Among the existing methods, real-time monitoring of RSW-related process signals has become a promising approach to actualize the online evaluation of weld expulsion. However, the inherent correlation between the process signals and the expulsion intensity is still unclear. In this work, a commonly used process signal, namely, the electrode displacement and its instantaneous behavior when expulsion occurs are systematically studied. Based upon experiments with various electrodes and workpieces, a nonlinear correlation between the weight of expelled metal and the sudden displacement drop accompanied by the occurrence of weld expulsion is observed, which is mainly influenced by electrode tip geometry but not by material strength or sheet thickness. The intrinsic relationship between this specific signal feature and the magnitude of expulsion is further explored through geometrical analysis, and a modified analytical model for online expulsion evaluation is finally proposed. It is shown that the improved model could be applied to domed electrodes with different tip geometries and varying workpieces ranging from low carbon steel to HSS. The error of expulsion estimation could be limited within ±20.4 mg (±2σ) at a 95% confidence level. This study may contribute to the online control of weld expulsion to the minimum level.

Corrosion-Fatigue Performance of High-Strength Riser Steels in Seawater and Sour Brine Environments

2011 ◽  
Author(s):  
Stephen J. Hudak ◽  
Guadalupe B. Robledo ◽  
Jeffrey Hawk
Keyword(s):  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Corrosion Fatigue ◽  
Cathodic Protection ◽  
High Strength Steels ◽  
High Strength ◽  
Fatigue Performance ◽  
Material Strength ◽  
Loading Frequency

Although new high-strength steels have recently been developed to meet the demands of increased reservoir pressures, and sour production fluids, the corrosion-fatigue performance of these new higher-strength materials is largely unknown. The goal of this study was to fill this knowledge gap by generating corrosion-fatigue data in two aggressive environments: 1) a sour production brine, and 2) seawater with cathodic protection. The focus of the current paper is on stress-life (S-N) corrosion-fatigue results in these environments, as well as a baseline air environment. Experiments were performed on five different steels with yield strengths ranging from 848 MPa to 1080 MPa. Prior frequency-scan results based on corrosion-fatigue crack growth rate data demonstrated that not all of these material-environment combinations exhibit a saturation frequency where the detrimental environmental effect approached a constant value as the cyclic loading frequency is decreased. Consequently, S-N tests were performed at different frequencies (0.01 Hz, 0.17 Hz, and 1 Hz), depending on the fatigue life regime, in attempting to match the loading frequencies experienced in service. Corrosion-fatigue occurred at stresses well below the fatigue endurance limit in laboratory air, and cyclic lives in the seawater with cathodic protection environment were found to be 2X to 10X less than those in the baseline air environment, while cyclic lives in the sour brine environment were found to be 30X to 100X less than those in the baseline air environment. In both environments, degradation was greatest at lower stresses in the high cycle fatigue regime. The effect of material strength level had little or no measurable effect on the S-N corrosion-fatigue performance, and the effect of cyclic frequency on the corrosion-fatigue performance was mixed. The S-N response to these two variables differed significantly from recently measured fatigue crack growth kinetics in these same materials that were performed in a companion study. Possible reasons for these differences are discussed.

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