Institute for Metal Forming Technology Prof. Dr.-Ing. Dr. h.c.

Klaus Siegert

Tool and Die Design for Deep Drawing AHSS

Prof. Dr.-Ing. Dr. h.c. Klaus Siegert Dipl.-Ing. M. Vulcan

Stuttgart University Institute for Metal Forming Technology

High Strength Steel Sheets Stretch Drawing of Flat Parts Controllable Draw Beads Cushion Systems and Die Design Summary
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Stuttgart University Institute for Metal Forming Technology Multiphase Steel Increase of strength by microstructural change Concerted control of grain refining by adding Titanium Solid solution hardening Diffusion of interst. N und C to increase the yield strength Embedding hard martensite parts in ferritic matrix Solid solution hardening by adding phosphorus Hardening by carbides of micro alloy elements Ti, Nb, V
1990 1995 2000

Isotropic Steel Higher-Strength IF-Steel

Bake Hardening Steel

Dual Phase Steel Phosphorus-Alloyed Steel

Micro-Alloyed Steel
1975 1980 1985

Source: Thyssen

Development of High Strength Steels

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Stuttgart University Institute for Metal Forming Technology Bake Hardening Steel HSLA 180BH HSLA 300BH

Elongation at Fracture A80 (%)

60 50 40 30 20 10

IF- Steel IF 180 IF 260

Phosphor alloyed HSLA 220P HSLA 300P

TRIP - Steel TRIP 700 TRIP 800

Complex-Phase Steel CP-W 800 CP-W 1000 MartensiteSteel MS-W 1000 MS-W 1200

Isotropic HSLA 220i HSLA 280i

Dual-Phase Steel DP 500 DP 600 Micro Alloyed HSLA 260 HSLA 420 400 500 600 700 800 900 1000

0 200

300

1100

Tensile Strength Rm (MPa)

Comparison of Different Steel Grades

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Stuttgart University Institute for Metal Forming Technology 900

kf
[N/mm] 700 600 500

TRIP 700

DP 600 DP 500

IF 260 400 300 200 100 0

Source: IFU

FePO4

0,05

0,15 Logarithmic True Strain

0,10

g
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Flow Curves of Actual Sheet Metals

Stuttgart University Institute for Metal Forming Technology

Yield Strength in MPa min High Strength Bake-Hardening Steels HSLA 180 BH HSLA 220 BH HSLA 260 BH HSLA 300 BH 180 220 260 300 240 280 320 360 max

UTS in MPa min max

Elong. at Fracture A80 in %

R-Value 0 45 90

300 320 360 400

380 400 440 480

32 30 28 26

rm = 1,9 rm = 1,5 rm = 1,4 rm = 1,3

High and Advanced High Strength Steels DP 600 DP 700 DP 800 TRIP 700 CP 800 MS 1200 793 1150 381 583 567 680 903 1350 574 735 869 850 23 16 10 20-30 14 6 0,7 0,8 0,9

Source: Birzer
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Stuttgart University Institute for Metal Forming Technology

High Strength Steel Sheets Stretch Drawing of Flat Parts Controllable Draw Beads Cushion Systems and Die Design Summary
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Stuttgart University Institute for Metal Forming Technology Punch Hydraulic Valves

Gripper Blankholder
Source: T. Krockenberger, IFU

Frame

Test Equipment for Stretch Drawing followed by Deep Drawing

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Stuttgart University Institute for Metal Forming Technology

Source: T. Krockenberger, IFU

Test Equipment for Stretch Drawing followed by Deep Drawing, Installed in Single Acting Hydraulic Press at IFU

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Stuttgart University Institute for Metal Forming Technology

Source: D. Vlahovic, IFU

First Stage: Clamping the Sheet

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Stuttgart University Institute for Metal Forming Technology

Source: D. Vlahovic, IFU

Second Stage: Predefined Stretching of the Sheet

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Stuttgart University Institute for Metal Forming Technology

Source: D. Vlahovic, IFU

Third Stage: Tool Closing

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Stuttgart University Institute for Metal Forming Technology

Source: D. Vlahovic, IFU

Last Stage: Deep Drawing of the Sun Roof Panel

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Stuttgart University Institute for Metal Forming Technology

Principal Strain after Deep Drawing

Principal Strain after Pre-Stretching

Source: D. Vlahovic, IFU

Results FEM Process Simulation

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Stuttgart University Institute for Metal Forming Technology

High Strength Steel Sheets Stretch Drawing of Flat Parts Controllable Draw Beads Cushion Systems and Die Design Summary
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Stuttgart University Institute for Metal Forming Technology Springback Reduction: Increased Wall Stresses in the Straight Sides by Driving the Active Drawbeads Upwards. Guideline:

Wall< 0,8 Fracture

Safety Factor

Fracture
Safety Distance

z, Wall, Drawbead z, Wall, Basic

Source: S. Beck, IFU

Desired Wall Stress Distribution

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Stuttgart University Institute for Metal Forming Technology

Safety Distance

Additional Force by Increased Blankholder Force and/or Increased Drawbead Height

Intention: Improved Wall Quality by Introducing Additional Forces

Source: S. Beck, IFU

Desired Punch Force Trajectory

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Stuttgart University Institute for Metal Forming Technology

Elastic Hinge Vertical Force Horizontal Force in the Sheet (Restraining Force) Side Wall Stress Sensor Punch Force in the Sheet

Load Cell

Source: S. Beck, IFU

Side Wall Stress Sensor

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Stuttgart University Institute for Metal Forming Technology

Drawbead 3

Connected Optional

Drawbead 2

Sensor

Drawbead 4

Drawbead 1

Source: S. Beck, IFU

Position of the Wall Stress Sensors and Position of the Drawbeads

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Stuttgart University Institute for Metal Forming Technology

350 Stress at Fracture 300

2

Stress in N/mm

250 200 150 100 50 0 0 20 40 60 Stroke in mm 80 100 120

Stress 1 Stress 2 Stress 3 Stress 4

Quelle: S. Beck, IFU

Side Wall Stress vs. Stroke for Constant Draw Bead Heights
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Stuttgart University Institute for Metal Forming Technology

r = 1/R

Source: S. Beck, IFU

Curvature of the Side Wall for Variable Draw Bead Heights vs. Stroke
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Stuttgart University Institute for Metal Forming Technology

Source: M. Beth

Springback Phenomena when Drawing U-Profiles

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Stuttgart University Institute for Metal Forming Technology

Sidewall of the Part, drawn without Drawbeads

Source: S. Beck, IFU

Sidewall of the Part, drawn with Controllable Drawbeads

Surface Quality with and without Controllable Drawbeads (Measured with the System Diffracto)

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Stuttgart University Institute for Metal Forming Technology

High Strength Steel Sheets Stretch Drawing of Flat Parts Controllable Draw Beads Cushion Systems and Die Design Summary
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Stuttgart University Institute for Metal Forming Technology

Box-Profile

C-Profile

Source: M. Hussermann, IFU

Design of Conventional Draw Dies

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Stuttgart University Institute for Metal Forming Technology

Blankholder Pressure:

4 ...

... 0 N/mm2

Source: M. Hussermann, IFU

Blankholder Pressure by the Box-Profile

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Stuttgart University Institute for Metal Forming Technology

Locally increased Blankholder Pressure

Blank

Draw Ring

Blankholder

FPin
Source: M. Hussermann, IFU

F Pin

FPin, increased

F Pin

Principle of the Segment-Elastic Blankholder

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Stuttgart University Institute for Metal Forming Technology

Draw Die with Segment-Elastic Blankholder, Prismatic Designed Draw Ring and 10-Point Cushion System Integrated into the Die

Prismatc Designed Draw Ring

Punch Segment-Eelastic Blankholder Guide Return Stroke Cylinders Stroke Measurement Servo Valves

Bottom Plate Hydraulic Cylinders

Source: M. Hussermann, IFU
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Stuttgart University Institute for Metal Forming Technology

Source: M. Hussermann, IFU

Hydraulic Multipoint Cushion System in the Die

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Stuttgart University Institute for Metal Forming Technology

Normal Pressure:

4,5 ...

... 0 N/mm2

Equal Pin Forces

Increase of 100% in the Middle Area

Source: M. Hussermann, IFU

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Stuttgart University Institute for Metal Forming Technology

Total Blankholder Force 530kN

Good Part with 68 mm Draw Depth

7 kN

102 kN

99 kN

13 kN

43 kN

24 kN

2 kN

90 kN

98 kN

52 kN

Source: M. Hussermann, IFU

Optimization of the Cushion Pin Forces

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Stuttgart University Institute for Metal Forming Technology

Die for the Deep Drawing of Longitudinal Beams with Cushion System integrated into the Die

Punch

Blankholder

Valves 18 Nytrogen Cylinders

Cables and sensors

Source: D. Haller, IFU
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Stuttgart University Institute for Metal Forming Technology

Die for the Deep Drawing of Longitudinal Beams with Cushion System integrated into the Die

Source: D. Haller, IFU

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Stuttgart University Institute for Metal Forming Technology

Experimental Die

Source: J. Hengelhaupt, IFU

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Stuttgart University Institute for Metal Forming Technology

Hydraulic HMI

Main Mobile Hydraulic Unit

Press HMI

10 Point Flexible Binder Die

20.000 kN Hydraulic Press at the IFU

IFU HMI

MOOG Controller Units

Source: IFU

HYDAC Power Unit

Cooling System

2 x Return Tank Units

2 x Bladder Accumulators Station (each 1 x 60 bar and 2 x 10 bar)

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Stuttgart University Institute for Metal Forming Technology

Source: M. Vulcan, IFU

Control system with Touch Screen to Adjust the Blankholder Pressure Area by Area

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Stuttgart University Institute for Metal Forming Technology

Nominal Value

Friction Force versus the Stroke Max. Wrinkle Height

Stroke

Actual Values Controller Ram Upper Binder Segment-elastic Blankholder Measuring Friction Force and Wrinkle Height

Cushion System integrated into the Die

Source: IFU

Design of Closed Loop Control of the BHF

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Stuttgart University Institute for Metal Forming Technology

Tool and Die Design for Deep Drawing AHSS

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Stuttgart University Institute for Metal Forming Technology

w w w . a u t o s t e e l . o r g

Great Designs in Steel is Sponsored by:

AK Steel Corporation Dofasco Inc. Mittal Steel Company Nucor Corporation Severstal North America Inc. United States Steel Corporation
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