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Forming-Induced Residual Stress and Material Properties of Roll-Formed High-Strength Steels

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Abstract

Martensitic steels are widely used in the automotive lightweight application but less understood in aspects of post-forming material properties. The steels show good ductility in roll forming but occasionally experience delayed (hydrogen) fracture issues, which are believed to be due to the formation of localized residual stress and a reduced product of strength and elongation. To characterize the effect of roll forming process on the formation of residual stress and material properties variation of martensitic steel components, this paper investigates the forming-induced longitudinal residual stress and material property variation in a roll-formed high-strength MS1180 automotive rocker panel. The finite element analysis results for residual stress are validated by neutron diffraction measurements. The numerical model is used to analyze the full evolution of residual stress during the roll forming process and the effect on material properties with major focus on the product of strength and elongation. It is found that the flower design, in particular the overbending stages, play a significant role in the formation of residual stress and the change in material properties. The product of strength and elongation is significantly reduced across the profile, in particular in the corners. The achieved understanding will assist researchers comprehend the material properties of roll-formed component and therefore assist future studies aimed at preventing the occurrence of hydrogen fracture.

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Abbreviations

AHSS:

Advanced high strength steel

EDM:

Electrical discharge machining

FEA:

Finite element analysis

MS:

Martensitic steel

PSE:

Product of strength and elongation

SEM:

Scanning electron microscope

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Acknowledgements

The authors acknowledge the authors Baosteel Co., Ltd. for providing the material properties of the experimental samples. This project is financially supported by Baosteel-Australia Joint Research and Development Centre (BAJC) BA17013 and Australian Centre for Neutron Scattering (ACNS, ANSTO) beam time proposals 4865 and 6499. The authors also would like to acknowledge the assistance of Emeritus Professor J.L. Duncan, Dr Scott Ding, Dr Aditya Deole, Mr Kang Wu in writing this paper.

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Authors and Affiliations

  1. Institute for Frontier Materials (IFM), Deakin University, Geelong, VIC, 3216, Australia

    Yong Sun, Yixin Duan, Rameshkumar Varma & Matthias Weiss

  2. School of Mechanical and Mining Engineering, The University of Queensland, St Lucia, Brisbane, QLD, 4072, Australia

    Yong Sun

  3. Australian Nuclear Science and Technology Organization (ANSTO), Lucas Heights, NSW, 2234, Australia

    Vladimir Luzin

  4. School of Engineering, The University of Newcastle, Callaghan, NSW, 2308, Australia

    Vladimir Luzin

  5. Research Institute, Baoshan Iron & Steel Co., Ltd., Shanghai, 201900, China

    Lei Shi

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  1. Yong Sun
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  2. Vladimir Luzin
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  3. Yixin Duan
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  4. Rameshkumar Varma
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  5. Lei Shi
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  6. Matthias Weiss
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Correspondence to Yong Sun.

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Sun, Y., Luzin, V., Duan, Y. et al. Forming-Induced Residual Stress and Material Properties of Roll-Formed High-Strength Steels. Automot. Innov. 3, 210–220 (2020). https://doi.org/10.1007/s42154-020-00112-2

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  • DOI: https://doi.org/10.1007/s42154-020-00112-2

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