Reducing the shear affected zone to improve the edge formability using a two-stage shear cutting simulation

Pätzold, Isabella; Stahl, Jens; Golle, Roland; Volk, Wolfram

doi:10.1016/j.jmatprotec.2023.117872

Cited by 8 publications

(6 citation statements)

References 23 publications

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“…Other tests are being developed to address this issue, such as the Diabolo test, however some aspects of testing conditions are not yet precisely defined. [5][6][7][8] The standard ISO 16630 requires specimen with a hole with 10 mm diameter in centre. It also prescribes that no hole shall be closer than 45 mm to the edge of specimen.…”

Section: Hole Expansion Test Principlementioning

confidence: 99%

Experimental Analysis of Crack Formation at Sheet Metal Edges

PETR,

NOVÁK,

TATÍČEK

et al. 2023

METAL Conference Proeedings

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During the pressing of sheet metal parts, cracks may form around the holes that weren't predicted by numerical simulations. These cracks are caused by the partial depletion of the forming capacity at the edges of the hole due to the preparation technology used, most often shearing. The aim of this article is to refine the simulation models by introducing boundary conditions to describe this condition. The Hole Expansion Test (HET), described in ISO 16630 and currently the only worldwide standardised method for determining the sensitivity of a material to edge crack formation, is used to determine the limiting deformation at the edge of the material. Materials commonly used in the automotive industry were chosen for the experiment. Holes were made in samples of each material according to ISO 16630 by shearing, laser cutting, and electro-discharge machining. The testing was carried out according to ISO 16630 at room temperature and the specimens were evaluated manually just before failure. The results obtained were evaluated and compared with theoretical premises. By refining simulation models and introducing boundary conditions that account for the depletion of forming capacity at the edges of holes, manufacturers can better predict and prevent the formation of cracks during the pressing of sheet metal parts. This can improve the quality and durability of automotive parts and lead to safer and more reliable vehicles.

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Section: Hole Expansion Test Principlementioning

confidence: 99%

Experimental Analysis of Crack Formation at Sheet Metal Edges

PETR,

NOVÁK,

TATÍČEK

et al. 2023

METAL Conference Proeedings

View full text Add to dashboard Cite

show abstract

“…In industries like the automotive industry, requirements for lightweight construction and crash safety have led to the use of modern steels, including advanced high strength steels [4]. This type of material is more sensitive to edge cracking in the forming processes, leading to the formation of edge cracks [4].…”

Section: Introductionmentioning

confidence: 99%

“…The condition of the edge and the occurrence of cracks in the material will depend on the cutting process used. In processes such as water-jet cutting, erosion, machining or polishing there will be almost no influence, while in processes where shear cutting occurs (punching and blanking, among others) there is a higher risk of edge cracking [4]. In shear cutting, the large deformation that is generated causes strain hardening, accompanied by a reduction in forming potential, damage to the microstructure and strong residual stress Metals 2024, 14, 616 2 of 21 fields.…”

Section: Introductionmentioning

confidence: 99%

“…In shear cutting, the large deformation that is generated causes strain hardening, accompanied by a reduction in forming potential, damage to the microstructure and strong residual stress Metals 2024, 14, 616 2 of 21 fields. Therefore, the process parameters will influence the lamination, burnish, fracture, and burr zones generated as a result of shearing [4].…”

Section: Introductionmentioning

confidence: 99%

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Study and Optimization of the Punching Process of Steel Using the Johnson–Cook Damage Model

Claver,

Acosta,

Barba

et al. 2024

Metals

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Sheet metal forming processes are widely used in applications such as those in the automotive or aerospace industries. Among them, punching is of great interest due to its high productivity and low operating cost. However, it is necessary to optimize these processes and adjust their parameters, such as clearance, shear force or tool geometry, to obtain the best finishes and minimize crack generation. Thus, the main objective of this research work is to optimize the punching process to achieve parts that do not require subsequent processes, such as deburring, by controlling the properties of the starting materials and with the help of tools such as design of experiments and simulations. In the present study, tensile tests were performed on three steels with different compositions and three sample geometries. The information obtained from these tests has allowed us to determine the parameters of the Johnson–Cook damage criteria. Moreover, punching was performed on real parts and compared with simulations to analyze the percentage of burnish surface. The results obtained show that the methodology used was correct and that it can be extrapolated to other types of die-cutting processes by reducing the percentage of surface fractures and predicting the appearance of cracks. Furthermore, it was observed that clearance has a greater influence than processing speed, while the minimum percentage of the burnish area was observed for the minimum values of clearance.

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“…Re-meshing was applied by Thipprakmas et al [10] and Basak et al [11] and generally involves creation of a new mesh based on the prior deformation of the mesh, where the results are mapped on to the new configuration. A combination of ALE and re-meshing was adopted by Pätzold et al [12] to benefit from both techniques. Unfortunately, both ALE and re-meshing have drawbacks.…”

Section: Introductionmentioning

confidence: 99%

Numerical modelling of shear cutting using particle methods

Sandin

Prieto

Hammarberg

et al. 2023

IOP Conf. Ser.: Mater. Sci. Eng.

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The use of Advanced High Strength Steel (AHSS) allows for lightweighting of sheet steel components, with maintained structural integrity of the part. However, AHSS grades show limitations in edge crack resistance, primarily influenced by sheared edge damage introduced by the shear cutting process. Numerical modelling of the shear cutting process can aid the understanding of the sheared edge damage, thus avoiding unforeseen edge cracking in the subsequent cold forming. However, the extreme deformations of the blank during the shear cutting process are likely to cause numerical instabilities and divergence using conventional Finite Element modelling. To overcome these challenges, this work presents the use of a particle-based numerical modelling method called the Particle Finite Element Method (PFEM). PFEM accurately solves some of the challenges encountered in shear cutting with the standard Finite Element method, such as large deformation, angular distortions, generation of new boundaries and presents an efficient way of transfer historical information from the old to the new mesh, minimising the results diffusion. The present work shows prediction of cut edge morphology of AHSS using a PFEM modelling scheme, where the numerical results are verified against experiments. With these results, the authors show new possibilities to obtain accurate numerical prediction of the shear cutting process, which promotes further advances in prediction of edge damaged related to shear cutting of AHSS.

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Reducing the shear affected zone to improve the edge formability using a two-stage shear cutting simulation

Cited by 8 publications

References 23 publications

Experimental Analysis of Crack Formation at Sheet Metal Edges

Experimental Analysis of Crack Formation at Sheet Metal Edges

Study and Optimization of the Punching Process of Steel Using the Johnson–Cook Damage Model

Numerical modelling of shear cutting using particle methods

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