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Technical Briefs

An Engineering Approach to Improve the Stamping Robustness of High Strength Steels

[+] Author and Article Information
Wu-rong Wang1

School of Mechanical Engineering, Shanghai JiaoTong University, Shanghai 200240, Chinawangwurong@sjtu.edu.cn

Bo Hou

School of Mechanical Engineering, Shanghai JiaoTong University, Shanghai 200240, China

Zhong-qin Lin

School of Mechanical Engineering and State Key Laboratory of Mechanical System and Vibration, Shanghai JiaoTong University, Shanghai 200240, China

Z. Cedric Xia

Research & Advanced Engineering, Ford Motor Company, Dearborn, MI 48121

1

Corresponding author.

J. Manuf. Sci. Eng 131(6), 064501 (Oct 26, 2009) (5 pages) doi:10.1115/1.4000333 History: Received November 24, 2008; Revised September 04, 2009; Published October 26, 2009

High strength steels (HSSs) are one of the light-weight sheet metals well suited for reducing vehicle weight due to their higher strength-to-weight ratio. However, HSS tend to have bigger variations in their mechanical properties due to more complex rolling techniques involved in the steel-making process. Such uncertainties, when combined with variations in the process parameters such as friction and blank holder force, pose a significant challenge in maintaining the robustness of HSS sheet metal stamping. The paper presents a systematic and robust approach, combining the power of the finite element method and stochastic statistics to decrease the sensitivity of HSS stamping in the presence of above-mentioned uncertainties. First, the statistical distribution of sheet metal properties of selected HSS is characterized from a material sampling database. Then a separate interval adaptive response surface methodology (RSM) is applied in modeling sheet metal stamping. The new method significantly improves the model accuracy when compared with the conventional RSM within a single interval. Finally, the Monte Carlo method is employed to simulate the stochastic response of material/process variations to stamping quality and to provide optimal process parameter designs to reduce the sensitivity of these effects. The experiment with the obtained optimal process design demonstrates the improvements of stamping robustness using small-batch experiments.

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Copyright © 2009 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

The classic model for robust design

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Figure 2

The flowchart of robust design for stamping

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Figure 3

The double oval part

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Figure 4

The illustration for the definition of safety margin

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Figure 5

The influence pie chart for the controlling factors

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Figure 6

The histograms of the calculated MSM for the three combination sets (a) (26, 0.200), (b) (27, 0.250), and (c) (27, 0.275)

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Figure 7

The binder tool with the drawbead

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Figure 8

The stamped parts with DP590MPa sheet material

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