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Analysis of crack for complex structural parts and simulation optimization during hot forming

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Abstract

Based on the crack mechanism of hot forming, the causes of cracks occurring during the hot forming of complex structural parts were investigated in this study. High temperature flow stress model of ultrahigh strength steel (UHSS) BR1500HS was established using the true stress–strain curves of BR1500HS in high-temperature tensile. A finite element model (FEM) was built to investigate the causes of defects in hot forming, particularly the necking occurring at the end parts in plan stress status. Then, hot forming process and structure optimizing methods were proposed. According to the results of numerical simulation, it can be concluded that the indirect hot forming process can avoid forming defects and optimize preforming drawing height to 24.5 mm. Through changing the end size of blank to control the metal flow, crack occurring at the end of parts can be solved, since the material in two-way tensile stress state can flow compensation in one direction and therefore reduce the flow resistance. The experimental results are in good agreement with numerical simulation results, which indicates that the proposed method can avoid defects and meet the design requirements.

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Authors and Affiliations

  1. College of Materials Science and Engineering, Chongqing University, Chongqing, 400044, China

    Xin Shang, Jie Zhou, Fang Zhuo & Yan Luo

Authors
  1. Xin Shang
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  2. Jie Zhou
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  3. Fang Zhuo
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  4. Yan Luo
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Correspondence to Jie Zhou.

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Shang, X., Zhou, J., Zhuo, F. et al. Analysis of crack for complex structural parts and simulation optimization during hot forming. Int J Adv Manuf Technol 80, 373–382 (2015). https://doi.org/10.1007/s00170-015-6990-9

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  • DOI: https://doi.org/10.1007/s00170-015-6990-9

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