Cockcroft-Latham Hasar Modeli Kullanılarak DP800 İleri Mukavemetli Çelik Delme-Zımbalama İşleminde Yüzey ve Boyut Olayların Değerlendirilmesi

Öz

Bu çalışma, yüksek mukavemet-ağırlık oranı nedeniyle otomotiv bileşenlerinde yaygın olarak kullanılan DP800 gelişmiş yüksek dayanımlı çeliğin (AHSS) delme davranışının nicel ve orijinal bir araştırmasını sunmaktadır. 1,5 mm kalınlığındaki DP800 saclar üzerinde yapılan deneysel testler, düzgün uzama davranışıyla birlikte ~900 MPa'lık maksimum gerçek gerilmeyi ortaya koymuştur. Beş farklı delme geometrisi değerlendirilmiştir; bunlar arasında P16 delme en pürüzsüz kesme yüzeyini ve en düşük çapak yüksekliğini (0,08 mm) üretirken, düz delme 0,11 mm vermiştir. Cockcroft-Latham (C-L) hasar modeli kullanılarak gerçekleştirilen sonlu elemanlar simülasyonları, deneysel sonuçlarla uyumlu olan C = 1,5'lik bir kritik hasar sabitini doğrulamıştır. Kesme bölgesi toplam sac kalınlığının yaklaşık %28'ini oluşturmaktadır ve boyutsal doğruluk ölçümleri, P16 delmenin nominal 20 mm'ye en yakın delik çaplarına ulaştığını göstermiştir. AHSS'nin genel davranışına odaklanan önceki çalışmalardan farklı olarak, bu çalışma DP800 delme mekaniği ve yüzey kalitesinin ayrıntılı bir nicel analizini sunmaktadır. Bulgular, takım geometrisi optimizasyonu ve hasar tahmini konusunda yeni bilgiler sunarak, AHSS şekillendirme operasyonlarında üretim hassasiyetini ve süreç güvenilirliğini artırmak için pratik kılavuzlar sunmaktadır.

Anahtar Kelimeler

• Dual-phase steels
• punching
• shear surface
• FEA

Proje Numarası

yok

Evaluation of Surface and Dimensional Phenomena in Punching of DP800 Advanced Strength Steel Utilising The Cockcroft-Latham Damage Model

Öz

This study presents a quantitative and original investigation of the punching behaviour of DP800 advanced high-strength steel (AHSS), widely used in automotive components due to its high strength-to-weight ratio. Experimental tests on 1.5 mm thick DP800 sheets revealed a maximum true stress of ~900 MPa, accompanied by uniform elongation behaviour. Five distinct punch geometries were evaluated, among which the P16 punch produced the smoothest cutting surface and the lowest burr height (0.08 mm), while the flat punch yielded 0.11 mm. Finite element simulations performed using the Cockcroft–Latham (C–L) damage model confirmed a critical damage constant of C = 1.5, which agrees with the experimental results. The shear zone accounted for approximately 28% of the total sheet thickness, and dimensional accuracy measurements indicated that the P16 punch achieved hole diameters closest to the nominal 20 mm. Unlike previous studies that primarily focused on the general behaviour of AHSS, this work provides a detailed quantitative analysis of DP800 punching mechanics and surface quality. The findings deliver novel insights into tool-geometry optimisation and damage prediction, offering practical guidelines for improving manufacturing precision and process reliability in AHSS forming operations.

Anahtar Kelimeler

• Dual-phase steels
• punching
• shear surface
• FEA

Destekleyen Kurum

yok

Proje Numarası

yok

Teşekkür

yok

Kaynakça

1. [1] S. Sadagopan, D. Urban, C. Wong, M. Huang, B. Yan, Formability Characterization of a New Generation High Strength Steels, Golden, CO (United States), (2003).
2. [2] B. Demir, M. Erdoǧan, The hardenability of austenite with different alloy content and dispersion in dual-phase steels, J Mater Process Technol, 208 75–84. (2008).
3. [3] B. Demir, K.B. Ali, H. Gürün, M. Acarer, An investigation of the shearing performance and sheared surface characterisation of ultra-strength DP steel-Al explosive welded plate composite, The International Journal of Advanced Manufacturing Technology 126, 1845–1861, (2023).
4. [4] S. Şeras, B. Demi̇r, Manufacturing of Low and High-carbon TRIP Steels by Modeling CCT Diagrams, Design of Microstructure Maps and Tensile Properties, Journal of Politechnic, 28, 1165–1173, (2023).
5. [5] M. Tisza, Development of Lightweight Steels for Automotive Applications, Engineering Steels and High Entropy-Alloys (2020).
6. [6] Y. Abe, K. Morı, Y. Suzuı, Effect of Quality of Sheared Edge on Formability of Hole Expansion of Ultra High Strength Steel Sheets, Journal of the Japan Society for Technology of Plasticity 50, 414–418, (2009).
7. [7] A. Karelova, C. Krempaszky, E. Werner, P. Tsipouridis, T. Hebesberger, A. Pichler, Hole Expansion of Dual‐phase and Complex‐phase AHS Steels ‐ Effect of Edge Conditions, Steel Res Int, 80.1, 71-77, (2009).
8. [8] M. Sigvant, J. Falk, J. Pilthammar, Experiments and FE-simulations of stretch flanging of DP-steels with different shear cut edge quality, J Phys Conf Ser 896 (2017).

9. [9] Chen, X., Jiang, H., Cui, Z., Lian, C., & Lu, C. Hole expansion characteristics of ultra-high strength steels. Procedia Engineering, 81, 718-723, (2014).
10. [10] K.I. Mori, Review of Shearing Processes of High Strength Steel Sheets, Journal of Manufacturing and Materials Processing, 4.2, 54, (2020).
11. [11] C. Pu, D. Zhou, P. Makrygiannis, W. Wu, Y. Jia, F. Zhu, C. Du, Y.W. Wang, A Comprehensive Study of Hole Punching Force for AHSS, SAE Technical Papers 2018-April (2018).
12. [12] N.A. Jaafar, A.B. Abdullah, Z. Samad, Effect of punching die angular clearance on punched hole quality of S275 mild steel sheet metal, The International Journal of Advanced Manufacturing Technology, 101:5, 101, 1553–1563, (2018).
13. [13] C. Pu, D. Zhou, P. Makrygiannis, W. Wu, Y. Jia, F. Zhu, C. Du, Y.W. Wang, A Comprehensive Study of Hole Punching Force for AHSS, SAE Technical Papers, (2018).
14. [14] A. Schenek, M. Liewald, Punching with a slant angle - cutting surface quality, ESAFORM, (2021).
15. [15] A.; H.; Acosta, E.; Barba, J.P.; Fuertes, A.; Torres, J.A.; García, R.; Luri, D. Salcedo, G. Winiarski, C. Bellini, A. Claver, A.H. Acosta, E. Barba, J.P. Fuertes, A. Torres, J.A. García, R. Luri, D. Salcedo, Study and Optimization of the Punching Process of Steel Using the Johnson–Cook Damage Model, Metals 2024, 14, 616, (2024).
16. [16] P.W. Myint, S. Hagihara, T. Tanaka, S. Taketomi, Y. Tadano, Application of Finite Element Method to Analyze the Influences of Process Parameters on the Cut Surface in Fine Blanking Processes by Using Clearance-Dependent Critical Fracture Criteria, Journal of Manufacturing and Materials Processing, 2, 26, 2, (2018).
17. [17] D.K. Matlock, J.G. Speer, Third Generation of AHSS: Microstructure Design Concepts, Microstructure and Texture in Steels, 185–205, (2009).
18. [18] F. Hayat, B. Demir, M. Acarer, Tensile shear stress and microstructure of low-carbon dual-phase Mn-Ni steels after spot resistance welding, Metal Science and Heat Treatment, 49:9, 484–489 (2007).
19. [19] Y. Wang, L. Cao, D. Hao, al -, D. Collet, M. Alamir, D. di Domenico, D. Diaz, I. Paetzold, F. Dittmann, M. Feistle, R. Golle, P. Haefele, H. Hoffmann, W. Volk, Influence of shear cutting parameters on the fatigue behavior of a dual-phase steel, J Phys Conf Ser, 896, 012107, (2017).
20. [20] D. Matlock, J. Speer, E. De Moor, P. Gibbs, Recent developments in advanced high strength sheet steels for automotive applications: an overview, Jestech 15, 1–12, (2012).
21. [21] B. Demir, An investigation on the production of dual-phase steel from AISI4140 and its impact strength at different martensite volume fractions, Metallofizika i Noveishie Tekhnologii 29 (2007).
22. [22] K. Isik, G. Gerstein, F. Gutknecht, T. Clausmeyer, F. Nürnberger, H.J. Maier, A.E. Tekkaya, Investigations of ductile damage in DP600 and DC04 deep drawing steel sheets during punching, Procedia Structural Integrity 2, 673–680, (2016).
23. [23] R. Hambli, Finite element simulation of fine blanking processes using a pressure-dependent damage model, J Mater Process Technol 116, 252–264. (2001).
24. [24] Y. Wu, J. Uusitalo, A.J. DeArdo, Investigation of the critical factors controlling sheared edge stretching of ultra-high strength dual-phase steels, Materials Science and Engineering A, 828, (2021).
25. [25] A. Yetgin, B. Demir, H. Gürün, K.B. Ali, Analytical and Experimental Investigation of Product Geometry and Dimensional Accuracy in the Punching Process of AA 1050 and AA 1070 Sheets, Gazi University Journal of Science, 37, 939–951, (2024).
26. [26] S.Y. Luo, Effect of the geometry and the surface treatment of punching tools on the tool life and wear conditions in the piercing of thick steel plate, J Mater Process Technol 88, 122–133, (1999).
27. [27] Z. Tekiner, M. Nalbant, H. Gürün, An experimental study for the effect of different clearances on burr, smooth-sheared and blanking force on aluminium sheet metal, Mater Des 27, 1134–1138, (2006).
28. [28] H. Gürün, M. Göktaş, A. Güldaş, Experimental Examination of Effects of Punch Angle and Clearance on Shearing Force and Estimation of Shearing Force Using Fuzzy Logic, Transactions of FAMENA 40, 19–28, (2016).
29. [29] C. Pu, D. Zhou, P. Makrygiannis, W. Wu, Y. Jia, F. Zhu, C. Du, Y.W. Wang, A Comprehensive Study of Hole Punching Force for AHSS, SAE Technical Papers 2018-April (2018).
30. [30] A. Claver, A.H. Acosta, E. Barba, J.P. Fuertes, A. Torres, J.A. García, R. Luri, D. Salcedo, Study and Optimization of the Punching Process of Steel Using the Johnson–Cook Damage Model, Metals (Basel) 14 (2024).
31. [31] P.W. Myint, S. Hagihara, T. Tanaka, S. Taketomi, Y. Tadano, Determination of the Values of Critical Ductile Fracture Criteria to Predict Fracture Initiation in Punching Processes, Journal of Manufacturing and Materials Processing 1 (2017).
32. [32] K.B. Ali, B. Demir, H. Gürün, M. Acarer, Influence of Punch Shapes on Forces and Part Quality in the Punching of Explosively Welded DP600, Al1100, and DP600-Al1100 Composite Plates, Transactions of FAMENA 46, 58–68, (2022).
33. [33] A. Schenek, M. Görz, M. Liewald, K.R. Riedmüller, Data-Driven Derivation of Sheet Metal Properties Gained from Punching Forces Using an Artificial Neural Network, Key Eng Mater 926, 2174–2182, (2022).
34. [34] M. Oyane, T. Sato, K. Okimoto, S. Shima, Criteria for ductile fracture and their applications, Journal of Mechanical Working Technology 4, 65–81, (1980).
35. [35] S.P. Tsiloufas, R.L. Plaut, Ductile Fracture Characterisation for Medium Carbon Steel Using Continuum Damage Mechanics, Materials Sciences and Applications 3, 745–755, (2012).
36. [36] Y. Lou, H. Huh, Extension of a shear-controlled ductile fracture model considering the stress triaxiality and the Lode parameter, Int J Solids Struct 50, 447–455, (2013).
37. [37] B. Demir, H. Gürün, K.B. Ali, M. Acarer, The punching of DP1000 automotive steel–Al laminate composite fabricated by explosive welding: Effect of tool geometry on cutting force and cut surfaces, Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, in press (2024).
38. [38] K.I. Mori, Review of shearing processes of high strength steel sheets, Journal of Manufacturing and Materials Processing 4 (2020).
39. [39] R. Narayanasamy, C. Sathiya Narayanan, Palani Padmanabhan & T. Venugopalan, Effect of mechanical and fractographic properties on hole expandability of various automobile steels during hole expansion test, The International Journal of Advanced Manufacturing Technology, 47, 365–380, (2010).
40. [40] C. Chiriac, H.-C. Shih, Investigations on Sheared Edge Damage of Dual Phase 780 Steel, Materials Science and Technology, 617–626, (2011).
41. [41] Ö. Pamuk, A. Durgutlu, The Effect of Explosive Ratio on Microstructure, Hardness and Fatigue Properties of AISI 430–S235JR Materials Joined by Explosive Welding Method, Journal of the Faculty of Engineering and Architecture of Gazi University 34, 905–914. (2019).
42. [42] C. Pu, D. Zhou, P. Makrygiannis, W. Wu, Y. Jia, F. Zhu, C. Du, Y.W. Wang, A Comprehensive Study of Hole Punching Force for AHSS, SAE Technical Papers, April, 1–9, (2018).
43. [43] A. Durgutlu, B. Gülenç, G. Üniversitesi, Weldabılıty Of Staınless Steel To Copper Plates By Explosive Welding And The Effect Of Explosıve Ratio On The Joınt Interface, Journal of Polytechnic 5, 243–248, (2002).
44. [44] H. Jia, C. Pu, J. Burton, F. Zhu, Y. Wang, Numerical Investigation of Optimal Rooftop Punch Shape for Force Reduction and Dimensional Accuracy Control, in: WCX SAE World Congress Experience, SAE International, (2019). [45] A. E. Saier, Theoretical and experimental investigation of punching process of DP800 automotive steel sheet with different punch tips, MSc. Thesis, Institute of Graduate Education, Karabuk University, (2021)