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Investigation on the effect of friction and material behavior models on the springback simulation precision: application to automotive part B-Pillar and material TRIP800 steel

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Abstract

Automakers continuously develop new steel grades with high performance for the automotive industry: For example, dual phase steel (DP) and transformation-induced plasticity steel (TRIP) are now widespread. The use of these grades improves the crashworthiness of automotive bodies and allows a significant weight reduction for cars. However, these materials raise new challenges for manufacturers, especially for springback prediction, which affects the manufacturing precision. In this study, the influence of material models and coefficients of friction on the springback prediction is investigated. The stamping of an industrial example of the B-Pillar is analyzed using three coefficients of friction (\(\mu\)=0.08, \(\mu\)=0.12, \(\mu\)=0.16), four constitutive models (Hockett-Sherby, Swift, SHS, and mixed), and three yield functions (Barlat 91, Hill 90 and Hill 48). All numerical simulations are realized using Pam-Stamp software and compared with measurements. Based on the obtained results, a classification of different parameters is presented.

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Data availability

Forming of industrial parts realized at ArcelorMittal, Post-processing and analyze of results realized at the laboratory LGM

Code availability

Commercial code Pam-Stamp 2G.

Abbreviations

DP:

Dual phase

TRIP:

Transformation-induced plasticity

TRIP800:

Cold rolled transformation induced plasticity steel

HS:

Hockett-Sherby

AHSS:

Advanced high strength steel

SHS:

Swift-Hockett-Sherby

FEA:

Finite element analyses

TWIP:

Twinning-induced plasticity

HSS:

High strength steels

FE:

Finite element

SB:

Springback

SBmax :

Maximum value of springback

SBmin:

Minimum value of springback

∆SBmax :

Maximum variation of displacement

∆SBmin :

Minimum variation of displacement

CAD:

Computer aided design

BHF:

Blank-holder force

SPD:

Punch speed

\(K\) :

Hardening coefficient

\(n\) :

Strain hardening exponent

\(X\) :

Kinematic hardening

\(X_{sat}\) :

Saturation value of the norm |X|

\(C_{x}\) :

Saturation rate of \(X\)

\(R\) :

Isotropic hardening

\(R_{0}\) :

Initial value of the yield stress

\(R_{sat}\) :

Saturation value of \(R\)

\(C_{r}\) :

Saturation rate of \(R\)

\(f\) :

Quadratic yield criterion

\(F,G,H,L,M,N\) :

Material constants

\(r_{0} ,r_{45} ,r_{90}\) :

Lankford coefficients in three anisotropic directions 0°, 45° and 90°

\(x,y,z\) :

Orthogonal axes of orthotropic

\(m\) :

Material constant

\(g\) :

Barlat 91 yield function

\({\varvec{S}}\) :

Deviator stress tensor

\(S_{1} ,S_{2} ,S_{3}\) :

Principal values of the isotropic plastic equivalent deviatory stress tensor \({\varvec{S}}\)

\(a,b,c,d,e,f,g,h\) :

Coefficients determined from uniaxial and shear yield stresses in the directions of the symmetry axes

\(Th_{ini} \, \) :

Initial sheet thickness

\(\mu\) :

Friction coefficient

\(\sigma\) :

Flow stress

\(\varepsilon_{0}\) :

Pre-strain

\(\overline{\varepsilon }^{p}\), \(\varepsilon\) :

Effective accumulated plastic strain

\(\sigma_{sat}\) :

Saturation stress

\(\sigma_{0}\) :

Initial yield stress

\(\alpha\) :

Weight factor

\(\sigma_{ij}\) :

Equivalent tensile stress

\(\sigma_{xx} ,\sigma_{yy} ,\sigma_{zz} ,\sigma_{xy} ,\sigma_{yz} ,\sigma_{zx}\) :

Components of the Cauchy stress tensor

\(\sigma_{yy}^{1} ,\sigma_{yy}^{b}\) :

Yield stress obtained from uniaxial and equi-biaxial tensions, respectively

\(\alpha ,\beta ,\gamma\) :

Constant parameters of material determined from the uniaxial and biaxial tension tests

\(\sigma_{11} ,\sigma_{22} ,\sigma_{33} ,\sigma_{12} ,\sigma_{23} ,\sigma_{13}\) :

Stress tensor components

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Acknowledgements

The authors thank the company ArcelorMittal for the measurements and for the funding of a part of this research.

Funding

ArcelorMittal Maizières Research

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Authors and Affiliations

  1. Laboratory of Mechanical Engineering, National Engineering School of Monastir, University of Monastir, Avenue Ibn Eljazzar, 5019, Monastir, Tunisia

    Slim Ben-Elechi, Riadh Bahloul & Sami Chatti

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  1. Slim Ben-Elechi
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  2. Riadh Bahloul
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  3. Sami Chatti
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Correspondence to Slim Ben-Elechi.

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Ben-Elechi, S., Bahloul, R. & Chatti, S. Investigation on the effect of friction and material behavior models on the springback simulation precision: application to automotive part B-Pillar and material TRIP800 steel. J Braz. Soc. Mech. Sci. Eng. 44, 380 (2022). https://doi.org/10.1007/s40430-022-03670-0

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