0
Research Papers

Investigation on Shearing and Local Formability of Hot-Rolled High-Strength Plates

[+] Author and Article Information
Liang Dong

State Key Laboratory of Mechanical System
and Vibration,
Shanghai Key Laboratory of Digital Manufacture
for Thin-Walled Structures,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: dliang123@sjtu.edu.cn

Shuhui Li

State Key Laboratory of Mechanical System
and Vibration,
Shanghai Key Laboratory of Digital Manufacture
for Thin-Walled Structures,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: lishuhui@sjtu.edu.cn

Ji He

State Key Laboratory of Mechanical System
and Vibration,
Shanghai Key Laboratory of Digital Manufacture
for Thin-Walled Structures,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: benbenhj@sjtu.edu.cn

Ronggao Cui

State Key Laboratory of Mechanical System
and Vibration,
Shanghai Key Laboratory of Digital Manufacture
for Thin-Walled Structures,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: cuironggao@126.com

1Corresponding author.

Manuscript received September 14, 2015; final manuscript received May 13, 2016; published online June 20, 2016. Assoc. Editor: Edmund Chu.

J. Manuf. Sci. Eng 138(9), 091001 (Jun 20, 2016) (13 pages) Paper No: MANU-15-1477; doi: 10.1115/1.4033660 History: Received September 14, 2015; Revised May 13, 2016

In order to evaluate the shearing quality, the material inhomogeneity through thickness after shearing is introduced by the authors. This study investigates the shearing and local formability of hot-rolled high-strength steel (HSS) plate, which is generally exploited for the manufacturing of the beam of heavy trucks. Various kinds of plates with different thicknesses and strengths are used to figure out the effect of material properties on the shearing quality. Both the shear surface morphology and microhardness distribution of the sheared edge are considered for evaluating the influence of the sheared-edge quality on local formability during the following forming process. Vickers hardness tests are conducted to analyze the microhardness distribution on the shear surface, which is proved to have significant effect on the local formability of the sheared edge. Furthermore, two kinds of bending tests and simulation are employed to study the edge cracking phenomenon, and the results indicate that the junctional zone of burnished zone and fracture zone, which is defined as peak hardness zone (PHZ), has a significant impact on major strain distribution on shear surface in the side bending test and this region is the main cause of edge cracking in normal bending test.

Copyright © 2016 by ASME
Your Session has timed out. Please sign back in to continue.

References

Kuziak, R. , Kawalla, R. , and Waengler, S. , 2008, “ Advanced High Strength Steels for Automotive Industry,” Arch. Civ. Mech. Eng., 8(2), pp. 103–117. [CrossRef]
Hatanaka, N. , Yamaguchi, K. , and Takakura, N. , 2003, “ Finite Element Simulation of the Shearing Mechanism in the Blanking of Sheet Metal,” J. Mater. Process. Technol., 139(1–3), pp. 64–70. [CrossRef]
Taupin, E. , Breitling, J. , Wu, W.-T. , and Altan, T. , 1996, “ Material Fracture and Burr Formation in Blanking Results of FEM Simulations and Comparison With Experiments,” J. Mater. Process. Technol., 59(1–2), pp. 68–78. [CrossRef]
Hatanaka, N. , Yamaguchi, K. , Takakura, N. , and Lizuka, T. , 2003, “ Simulation of Sheared Edge Formation Process in Blanking of Sheet Metals,” J. Mater. Process. Technol., 140(1–3), pp. 628–634. [CrossRef]
Lemiale, V. , Chambert, J. , and Picart, P. , 2009, “ Description of Numerical Techniques With the Aim of Predicting the Sheet Metal Blanking Process by FEM Simulation,” J. Mater. Process. Technol., 209(5), p. 2723–2734. [CrossRef]
Hu, X. H. , Choi, K. S. , Sun, X. , and Golovashchenko, S. F. , 2014, “ Edge Fracture Prediction of Traditional and Advanced Trimming Processes for AA6111-T4 Sheets,” ASME J. Manuf. Sci. Eng., 136(2), p. 021016. [CrossRef]
Liu, J. , Bai, Y. , and Xu, C. , 2013, “ Evaluation of Ductile Fracture Models in Finite Element Simulation of Metal Cutting Processes,” ASME J. Manuf. Sci. Eng., 136(1), p. 011010. [CrossRef]
Marouani, H. , Ben Ismail, A. , Hug, E. , and Rachik, M. , 2009, “ Numerical Investigations on Sheet Metal Blanking With High Speed Deformation,” Mater. Des., 30(9), pp. 3566–3571. [CrossRef]
Husson, C. , Correia, J. P. M. , Daridon, L. , and Ahzi, S. , 2008, “ Finite Elements Simulations of Thin Copper Sheets Blanking: Study of Blanking Parameters on Sheared Edge Quality,” J. Mater. Process. Technol., 199(1–3), pp. 74–83. [CrossRef]
Li, Y.-G. , Ye, Q. , Fan, F. , Bao, Y. , and Huang, Q.-X. , 2012, “ Finite Element Method Analysis of Effect of Blade Clearance on Plate Shearing Process,” J. Iron Steel Res. Int., 19(10), pp. 26–29. [CrossRef]
Goijaerts, A. M. , Govaert, L. E. , and Baaijens, F. P. T. , 2002, “ Experimental and Numerical Investigation on the Influence of Process Speed on the Blanking Process,” ASME J. Manuf. Sci. Eng., 124(2), pp. 416–419. [CrossRef]
Shim, K. H. , Lee, S. K. , Kang, B. S. , and Hwang, S. M. , 2004, “ Investigation on Blanking of Thin Sheet Metal Using the Ductile Fracture Criterion and Its Experimental Verification,” J. Mater. Process. Technol., 155–156, pp. 1935–1942. [CrossRef]
Gustafsson, E. , Oldenburg, M. , and Jansson, A. , 2016, “ Experimental Study on the Effects of Clearance and Clamping in Steel Sheet Metal Shearing,” J. Mater. Process. Technol., 229, pp. 172–180. [CrossRef]
Kalpakjian, S. , 1997, Manufacturing Processes for Engineering Materials, 3rd ed., Addison Wesley, Menlo Park, CA.
Samuel, M. , 1998, “ FEM Simulations and Experimental Analysis of Parameters of Influence in the Blanking Process,” J. Mater. Process. Technol., 84(1–3), pp. 97–106. [CrossRef]
Shih, H.-C. , and Shi, M. F. , 2011, “ An Innovative Shearing Process for AHSS Edge Stretchability Improvements,” ASME J. Manuf. Sci. Eng., 133(6), p. 061018. [CrossRef]
Li, S. , He, J. , Xia, Z. C. , Zeng, D. , and Hou, B. , 2014, “ Bifurcation Analysis of Forming Limits for an Orthotropic Sheet Metal,” ASME J. Manuf. Sci. Eng., 136(5), p. 051005. [CrossRef]
He, J. , Xia, Z. C. , Li, S. , and Zeng, D. , 2013, “ M–K Analysis of Forming Limit Diagram Under Stretch-Bending,” ASME J. Manuf. Sci. Eng., 135(4), p. 041017. [CrossRef]
Hasan, R. , Kasikci, T. , Tsurkrov, I. , and Kinsey, B. L. , 2013, “ Numerical and Experimental Investigations of Key Assumptions in Analytical Failure Models for Sheet Metal Forming,” ASME J. Manuf. Sci. Eng., 136(1), p. 011013. [CrossRef]
Levy, B. S. , and Tyne, C. J. , 2011, “ Review of the Shearing Process for Sheet Steels and Its Effect on Sheared-Edge Stretching,” J. Mater. Eng. Perform., 21(7), pp. 1205–1213. [CrossRef]
Tsoupis, I. , Hildering, S. , and Merklein, M. , 2014, “ Bending of High-Strength Low-Alloyed Steel With Respect to Edge Crack Sensitivity Caused by Shearing Operations,” Procedia Eng., 81, pp. 712–717. [CrossRef]
Shih, H.-C. , and Shi, M. F. , 2011, “ An Innovative Shearing Process for AHSS Edge Stretchability Improvements,” ASME J. Manuf. Sci. Eng., 133(6), p. 061018. [CrossRef]
Wang, K. , Greve, L. , and Wierzbicki, T. , 2015, “ FE Simulation of Edge Fracture Considering Pre-Damage From Blanking Process,” Int. J. Solids Struct., 71, pp. 206–218. [CrossRef]
Matsuno, T. , Nitta, J. , Sato, K. , Mizumura, M. , and Suehiro, M. , 2015, “ Effect of Shearing Clearance and Angle on Stretch-Flange Formability Evaluated by Saddle-Type Forming Test,” J. Mater. Process. Technol., 223, pp. 98–104. [CrossRef]
Sun, Q. , Chen, J. , and Pan, H. , 2015, “ Prediction of Edge Crack in Cold Rolling of Silicon Steel Strip Based on an Extended Gurson–Tvergaard–Needleman Damage Model,” ASME J. Manuf. Sci. Eng., 137(2), p. 021003. [CrossRef]
ABAQUS, 2011, “ ABAQUS Analysis User's Manual,” Version 6.11, Dassault Systèmes, Waltham, MA.
Bahloul, R. , Dal Santo, P. , and Potiron, A. , 2008, “ Optimisation of the Bending Process of High Strength Low Alloy Sheet Metal: Numerical and Experimental Approach,” Int. J. Mater. Form, 1(1), pp. 113–116. [CrossRef]
Zhang, P. , Li, S. X. , and Zhang, Z. F. , 2011, “ General Relationship Between Strength and Hardness,” Mater. Sci. Eng., 529, pp. 62–73. [CrossRef]
Cockcroft, M. G. , and Latham, D. J. , 1968, “ Ductility and the Workability of Metals,” J. Inst. Met., 96, pp. 33–39.

Figures

Grahic Jump Location
Fig. 1

(a) Schematic diagram of the straight edge open shear tools, (b) diagram of the test specimen, and (c) photograph of the sheared specimen

Grahic Jump Location
Fig. 2

The flexible shearing die used in this study

Grahic Jump Location
Fig. 3

Shearing die used in this study: (a) upper punch and (b) lower die

Grahic Jump Location
Fig. 4

Theoretical blanked profile HOR zone, HOB, height of fracture zone (HOF), and (β) fracture angle β

Grahic Jump Location
Fig. 5

The investigation paths of the microhardness test

Grahic Jump Location
Fig. 6

Two kinds of bending tests used in this study: (a) side bending test and (b) normal bending test

Grahic Jump Location
Fig. 7

Microphotographs and SEM pictures of the sheared edge: (a) microphotograph of the burnished zone, (b) microphotograph of the fracture zone, (c) SEM picture of the burnished zone, and (d) SEM picture of the fracture zone

Grahic Jump Location
Fig. 8

Surface topography of the sheared edge of BS700MCK2 with different thicknesses: (a) HOB, (b) HOR, and (c) fracture angle β

Grahic Jump Location
Fig. 9

Surface topography of the sheared edge of BS700MCK2 and BS960QC with same thickness: (a) HOB, (b) HOR, and (c) fracture angle β

Grahic Jump Location
Fig. 10

The sheared-edge hardness of BS700MCK2 with thickness of 6 mm

Grahic Jump Location
Fig. 11

The results of microhardness distribution of the sheared edge for BS700MCK2 with different thicknesses: (a) t = 3 mm, (b) t = 6 mm, and (c) t = 8 mm

Grahic Jump Location
Fig. 12

Result of strain distribution on the shear surface measured by DIC

Grahic Jump Location
Fig. 13

(a) Section points position and (b) major strain of section points through thickness at the bending radius at the end of the bending moment

Grahic Jump Location
Fig. 14

Testing equipment of normal bending tests

Grahic Jump Location
Fig. 15

(a) The loading curve of the normal bending test, and pictures of different stages: (b) original state t = 0 s, (c) cracks initiation t = 40 s, (d) cracks propagation t = 60 s, and (e) final fracture t = 150 s

Grahic Jump Location
Fig. 16

Limited punch stroke and max microhardness value of PHZ with different shear clearances for BS700 and BS960: (a) the limited punch stroke and (b) max microhardness value of PHZ

Grahic Jump Location
Fig. 17

Geometry of the sheared sample in normal bending simulation

Grahic Jump Location
Fig. 18

Flow curve for BS700

Grahic Jump Location
Fig. 19

Microhardness and yield stress of five different kinds of hot-rolled HSS

Grahic Jump Location
Fig. 20

(a) Mesh of transverse section and (b) the influence of mesh size on the simulation results

Grahic Jump Location
Fig. 21

The experimental and simulated load versus punch stroke

Grahic Jump Location
Fig. 22

Accumulated damage of PHZ as a function of the punch stroke

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In