Formability analysis of hot-rolled dual-phase steel during the multistage stamping process of wheel disc
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ORIGINAL ARTICLE
Formability analysis of hot-rolled dual-phase steel during the multistage stamping process of wheel disc Weijin Chen 1,2,3 & Hongwu Song 1 & Lucian Lazarescu 4 & Yong Xu 1 & Shi-Hong Zhang 1 & Dorel Banabic 4 Received: 6 May 2020 / Accepted: 17 August 2020 / Published online: 24 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract For reduction of vehicle weight and higher fatigue property, the hot-rolled dual-phase steel 700DP was developed to produce wheel disc with multistage stamping process. The wheel disc is one critical component of wheel system whose forming precision is extensively concerned. The critical area of the part characterizes nonlinear strain path during the multistage stamping process, which makes it difficult to accurately evaluate the formability through standard forming limit curve (FLC) method. The concept of equivalent plastic strain was reported to be strain path independent. Hence, in this paper, the formability of 700DP steel was studied through tensile test, Nakazima test, and two-step nonlinear formability test. It was certified that the modeling using the equivalent plastic strain–based FLC (ep-FLC) had better agreement with the two-step nonlinear test results. Then based on current die shape, the feasibility of 700DP steel for wheel disc with three-stage stamping process was studied by finite element method (FEM) with both traditional FLC and ep-FLC. Furthermore, the corresponding experiments were conducted for validation. The results show that the location and critical condition for the occurrence of fracture can be more exactly predicted by the ep-FLC compared with the traditional FLC. The process parameters such as the radius of die corner were then optimized by the modeling analysis. Finally, the wheel disc was successfully manufactured with high precision and sound mechanical property. Keywords Hot-rolled dual-phase steel . Formability during multistage stamping process . The equivalent plastic strain–based FLC . Fem . Wheel disc
1 Introduction Steel wheel of motor vehicles always consists of rim and disc, as shown in Fig. 1. Wheel disc is the critical component of wheel system to sustain the cyclic stress conditions in the actual service. Considering the bearing performance, the shape of wheel disc is usually designed to be complex, which increases the difficulty for manufacture. With a lot of practical experiences, multistage stamping process is commonly * Hongwu Song [email protected] 1
Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, People’s Republic of China
2
School of Materials Science and Engineering, University of Science and Technology of China, Hefei 230026, People’s Republic of China
3
Meishan Technology Center of Baosteel Central Research Institute, Nanjing 210039, People’s Republic of China
4
Department of Manufacturing Engineering, Technical University of Cluj-Napoca, 400641 Cluj-Napoca, Romania
selected to satisfy the demand of low cost and high efficiency in industry. It was indicate
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